Formula Student

Formula Student - Intake Manifold

This intake manifold was designed specifically for our Formula Student UK vehicle to improve engine breathing and increase overall performance. Using Fusion 360, the manifold was carefully modeled to optimize airflow, while ANSYS simulations were used to analyze pressure drop, velocity and turbulence throughout the system.

Design Overview

Isometric View

Isometric view of the intake manifold, designed to optimize air intake for improved engine performance.

Exploded View

Exploded view showing the different components of the intake manifold and their arrangement.

Cross-Sectional View

Cross-sectional view of the intake manifold, illustrating what's inside the manifold and how its put together.

Key Design Features

The intake manifold was designed with performance optimization in mind, particularly for Formula Student competition. The plenum was crafted with a curved and tapered design to ensure even air distribution across all cylinders, minimizing pressure waves and maintaining steady airflow. To further enhance this, the intake runners were carefully optimized for low to mid-range power, crucial for the vehicle’s acceleration. Their tapered shape allowed for efficient air acceleration into the cylinders, while a symmetrical layout ensured consistent airflow between cylinders, reducing power imbalances.

A single throttle body was centrally integrated into the manifold, ensuring smooth air entry with minimal disturbances. The design also provided for easy integration of sensors, such as MAP and throttle position sensors, to facilitate precise engine management. In terms of materials, lightweight and durable Nylon-12 was chosen for its strength, heat dissipation, ease of manufacturing (3D-printed), and weight-saving properties, offering an ideal balance of performance and durability.

Flow and pressure optimization was a key focus, with extensive CFD simulations guiding the refinement of internal geometry to minimize turbulence and pressure drop. The resulting design ensured maximum air velocity into the cylinders. Modularity was also a priority, allowing for quick disassembly of components via bolt-on flanges, which facilitated easy adjustments and maintenance.

Performance Simulations

Engine Simulation

The design process began with an engine simulation. This is where the design features were validated before modelling in CAD.

Flow Simulation

Flow simulation results showing optimal air velocity and minimized turbulence within the manifold, leading to better cylinder filling and enhanced power output.

Structural Simulation

Structural Simulation results showing stress and strain when intake is subject to negative pressure from the engine

Design Challenges

One of the biggest challenges was balancing airflow across all two cylinders, especially given the compact space available in the engine bay. Extensive simulation helped ensure that air distribution was even, avoiding power imbalances between cylinders. Additionally, weight-saving measures like using thin-walled components and optimized shapes were key to reducing the overall mass of the intake manifold.

Lessons Learned

Designing the intake manifold for Formula Student taught me valuable lessons in managing complex airflow dynamics and optimizing mechanical components for performance. It deepened my understanding of how small changes in design can lead to significant improvements in engine efficiency and overall vehicle performance.