Design and Development of an Intake Manifold for

Boosted Engine Application using 3D CFD Analysis

Ricardo India User Conference 2015
Ashish C. Borde, Vinod Kale, M.T.Nimbalkar, Amar Bakare
12.05.2015 Pune, India

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Slide 1

Tata Motors and Analysis Software

Engineering Research Centre - Engines

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Slide 2

Agenda Intake Manifold Design Methodology

1. Motivation
2. Traditional vs New Methodologies
3. Intake Manifold Boosted Engine Application
4. CAE Workflow
5. Steady State Simulation Methodology
6. Transient Simulation Methodology
7. Optimization Strategies
8. Results
9. Future Outlook

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Slide 3

Motivation
A properly designed Intake Manifold is vital for the optimal performance of
an IC Engine.
The main task of an Intake Manifold is to distribute air between cylinders
properly.
An uneven air distribution leads to:

non-uniform cylinder volumetric efficiency,

power loss
increased fuel consumption.

During the operation of an IC Engine, pressure waves occur inside the

Intake Manifold.
Depending on amplitude and phase of these pressure waves, filling of
cylinders can be affected positively and negatively.
The amplitude and phase of these pressure waves depend on:

Intake Manifold geometry.

Engine Speed.
Valve Timing.

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Slide 4

Agenda Intake Manifold Design Methodology

1. Motivation
2. Traditional vs New Methodologies
3. Intake Manifold Boosted Engine Application
4. CAE Workflow
5. Steady State Simulation Methodology
6. Transient Simulation Methodology
7. Optimization Strategies
8. Results
9. Future Outlook

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Slide 5

Traditional vs New Methodologies

Traditional Intake Manifold Design and Optimization is based on actual physical tests of various
geometries on test bench engine.
This trial and error method can be effective but is very expensive and time consuming.
Besides, this method cannot provide any information about the actual flow parameters &
structure inside the intake manifold.
Using Intake Manifold with Symmetrical geometry has been the design by choice.
We try to simulate the actual real world working conditions to get more effective & accurate
results.
To do that several techniques involving tests and numerical simulation are been used for years.
3D CFD Tools like Ricardo VECTIS plays a major role in reducing Time, Cost and get to the
best optimized design with few iterations.

3D CFD - Design Methodology

Predict
Ricardo VECTIS 3D CFD
For Flow in
Intake Manifold

Observe

Analyze

For Steady and Transient

Conditions

Improve
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Slide 6

Agenda Intake Manifold Design Methodology

1. Motivation
2. Traditional vs New Methodologies
3. Intake Manifold Boosted Engine Application
4. CAE Workflow
5. Steady State Simulation Methodology
6. Transient Simulation Methodology
7. Optimization Strategies
8. Results
9. Future Outlook

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Slide 7

Intake Manifold Boosted Engine Application

To Achieve an Optimal Intake Manifold, these parameters should be taken into consideration:
1.
2.
3.
4.
5.

Uniform distribution of air to all cylinders

Minimum possible resistance in Intake Manifold Runners
Properly designed Intake Manifold Geometry to utilize the pressure waves to improve induction process.
Eliminate the unnecessary turbulence and eddies in Intake Manifold.
Choose the Throttle Body Position correctly (often symmetrical to the plenum but dictated by packaging constraints).

Development Targets

Benchmarking
Initial Concept Design

NVH Simulation

Flow Rig Test

Performance Test
Durability Test
NVH Test
Laboratory Test

Simulation

3D CFD using Ricardo VECTIS

Performance Tuning

1D using Ricardo WAVE

Packaging

CAD Design
Support Design
Procurement
Validation

Re-Design for Production

Production Tooling

Intake Manifold Development Steps

Off-Tool Validation
Test Results
Dimension and Tolerances
Serviceability and Ease of Assembly

Engineering Approval
Pilot Validation
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S.O.P
Slide 8

Agenda Intake Manifold Design Methodology

1. Motivation
2. Traditional vs New Methodologies
3. Intake Manifold Boosted Engine Application
4. CAE Workflow
5. Steady State Simulation Methodology
6. Transient Simulation Methodology
7. Optimization Strategies
8. Results
9. Future Outlook

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Slide 9

CAE Workflow
Ricardo VECTIS
3D CFD
Simulation

Steady State Analysis

The Pressure Loss Coefficients for

individual runners can be determined.
3D CFD allows the designer to see what
the flow structure is like inside the
manifold.
Can be used to make the design ready for
unsteady state simulation.
The Boundary Conditions in Steady State
Simulation can be Mass Flow Rate,
Constant Static or Total Pressure

Transient Analysis

Steady State study can be fast and can

provide the loss coefficients but this
cannot provide any information about an
Intake Manifold performance in the
operating conditions.
Transient simulation can predict how an
Intake Manifold works under real world
conditions.
The Boundary Conditions are no longer
constant but time variant.
These Boundary Conditions are obtained
from the 1-D gas dynamics analysis by
using the Wave Code

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Slide 10

CAE Workflow
2. Performing Stitching
Operation and Geometry
Check of the 3-D Model in
Phase 1 of Ricardo VECTIS

1. Creation of a 3-D
Model of Intake Manifold

3D CAD Geometry

4. Setting-Up the PHASE 5

Setup in Ricardo VECTIS
for both Steady and
Unsteady State Simulation
with Boundary Conditions
from WAVE.

3. Generation of MESH
and Checking for the
quality of the MESH in
Ricardo VECTIS

5. Run the Simulation and

Monitoring the Stability of the
Simulation (Convergence)
using R-PLOT within the
acceptable residual limits.

6. Post Processing in R-DESK

for Mass Flow Rates, Pressure
Drops, Runner to Runner
Pressure Variations, Flow
Velocities at various crosssections., etc.

7. Study the
Results and
keep
Optimizing till
following
happens..

PHASE 1 VECTIS

PHASE 1 Mesh Setup

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PHASE 5 Setup

R-Plot Convergence Check

Slide 11

Agenda Intake Manifold Design Methodology

1. Motivation
2. Traditional vs New Methodologies
3. Intake Manifold Boosted Engine Application
4. CAE Workflow
5. Steady State Simulation Methodology
6. Transient Simulation Methodology
7. Optimization Strategies
8. Results
9. Future Outlook

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Slide 12

Steady State Simulation Methodology

1. Constant boundary conditions like Mass Flow Rate, Total Pressure or Static Pressure are
applied.
2. Analyze Individual runners 1 by 1.
3. Check for the velocity vectors and flow.
4. Take Chop Plots at various sections to check for eddies, pressure drop, recirculation or vortex
formation.
5. Try avoiding the use of Streamline plotting for post-processing at early stages.
6. Ensure good velocities and pressure drop variations from runner to runner within 3-4%.
7. Meeting all above criteria ensures a good Intake Manifold design.

Intake Manifold Mesh

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Intake Manifold Velocity Streamlines

Intake Manifold Plenum Density Variation

Slide 13

Agenda Intake Manifold Design Methodology

1. Motivation
2. Traditional vs New Methodologies
3. Intake Manifold Boosted Engine Application
4. CAE Workflow
5. Steady State Simulation Methodology
6. Transient Simulation Methodology
7. Optimization Strategies
8. Results
9. Future Outlook

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Slide 14

Transient Simulation Methodology

1. The same numerical mesh that was used for steady state simulation can be used here,
2. To obtain the proper boundary conditions, the 1-D gas dynamics code WAVE code is used.
3. Analyze the back flow into the runners.
4. Analyze the flow velocity vectors at various section in the plenum.
5. Check for how the Intake Manifold distributes the air to each cylinders in a transient run
condition.
6. Ensure making video files for unsteady state simulation.

1D Gas Domain

Solid Domain

1D Ricardo WAVE Engine Model

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Inlet and Outlet Boundary Conditions

Slide 15

Agenda Intake Manifold Design Methodology

1. Motivation
2. Traditional vs New Methodologies
3. Intake Manifold Boosted Engine Application
4. CAE Workflow
5. Steady State Simulation Methodology
6. Transient Simulation Methodology
7. Optimization Strategies
8. Results
9. Future Outlook

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Slide 16

Optimization Strategies
Optimization Suggestions for Intake Manifold for Boosted Engine Application:
1. Reduce sharp connections inside the Intake Manifolds.
2. Smoother Bell-Mouth design.
3. The Plenum Volume and Geometry play a major role in the broadband engine performance.
4. Optimize the Location of the throttle body and the entry angle from throttle to the plenum.
5. For a Boosted Engine it was also observed that the RAM effect phenomena has a positive
effect all throughout the rpm range.
6. It is suggested to do parametric study of:
Runner diameter & length,
Plenum volume & its geometry, etc.
as shown in the following figures for the Design and Development of a Boosted Engine Manifold.

Intake Manifold Runner Length

Intake Manifold Runner Diameter.

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Intake Manifold Plenum Volume

Intake Manifold Runner Shape and Angle

Slide 17

Agenda Intake Manifold Design Methodology

1. Motivation
2. Traditional vs New Methodologies
3. Intake Manifold Boosted Engine Application
4. CAE Workflow
5. Steady State Simulation Methodology
6. Transient Simulation Methodology
7. Optimization Strategies
8. Results
9. Future Outlook

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Slide 18

Results

Plenum Velocity Distribution

To refine the plenum volume and shape
To Direct the Intake Air

Plenum Pressure Distribution

To refine the plenum volume and shape
To reduce pressure drop

Plenum to Runner Velocity Variation

Runner to Runner Velocity Distribution

For efficient cylinder to cylinder filling dynamics
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Runner to Runner Pressure Distribution

To reduce coefficient of variation between cylinders

Plenum to Runner Pressure Variation

Slide 19

Results

Runner to Runner Velocity Variation To Check for Flow Velocities and to eliminate Velocity Drop Regions

Runner to Runner Pressure Variation To Check for Pressure Distribution and Drop and Reduce Pressure Variations

Runner to Runner Flow Check

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Slide 20

Agenda Intake Manifold Design Methodology

1. Motivation
2. Traditional vs New Methodologies
3. Intake Manifold Boosted Engine Application
4. CAE Workflow
5. Steady State Simulation Methodology
6. Transient Simulation Methodology
7. Optimization Strategies
8. Results
9. Future Outlook

Copyright, Confidential, Tata Motors Ltd

Slide 21

Future Outlook
CONCLUSION:

The procedure for Design and Development of an Intake Manifold for Boosted Engine Application has been
explained.
Ricardo VECTIS 3D CFD is a powerful and useful tool for Design and Development of an Intake Manifold.

FUTURE SCOPE OF WORK:

1. Coupling of 1D WAVE and 3D VECTIS for engine performance simulation using the New Optimized Intake
Manifold Design.
2. 3D CFD simulation using Ricardo VECTIS to understand EGR Distribution and percentage difference in EGR
concentration among the runners.
3. 3D CFD simulation using Ricardo VECTIS for both the Intake Manifold and Intake Port combined together.

1D-3D WAVE VECTIS Coupling

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3D VECTIS Simulation for EGR Distribution

Slide 22

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Slide 23