CFD-Driven Optimization of Intake Manifold Design for Enhanced Volumetric Efficiency and Performance in Formula SAE Internal Combustion Engines

Abstract

This study investigates the optimization of an internal combustion engine (ICE) intake manifold through the application of Computational Fluid Dynamics (CFD) analysis, aiming to enhance volumetric efficiency and overall engine performance, particularly within the context of Formula SAE applications. The research employs steady-state CFD simulations to rigorously assess airflow dynamics, pressure distribution, and turbulence characteristics across a variety of intake runner configurations. Critical design parameters, including runner length, plenum volume, and restrictor geometry, are meticulously analyzed to mitigate cylinder-to-cylinder variation and maximize airflow uniformity. The findings reveal that optimized intake manifold geometries, including straight-runner designs, can enhance turbulent kinetic energy by as much as 11% while concurrently diminishing flow disparities among cylinders. Supersonic flow conditions (Mach > 1) are detected in proximity to critical sections, thereby underscoring the necessity for precise geometric tuning to alleviate compressibility effects. The selection of materials, specifically Glass Fiber Reinforced Plastic (GFRP), is substantiated based on its thermal and structural appropriateness. This study emphasizes the effectiveness of CFD-driven design methodologies in reducing development costs and timeframes, all while facilitating performance enhancements. Future research endeavors should incorporate transient CFD models and experimental validation to further optimize dynamic engine performance in authentic racing scenarios.