Internal Combustion Engine

Induction Tuning
ME 468 Engine Design
Professor Richard Hathaway
Department of Mechanical and Aeronautical Engineering
Port Sizing Considerations
Swept and Displaced Volumes
Swept Volume/cylinder:


s A s
d
4
=
V
p
2
B s
=
t
V
s
= swept volume d
B
= bore diameter
s = stroke
s
s x A
p
Inlet Port
Note: In valve design the Volume which flows into
the cylinder must equal the volume which flows
through the inlet port. The velocity past the valve
must then be considerably greater than the velocity
in the cylinder.
Port Sizing and Mach Index (Z)
Mach Index is the ratio of the velocity of the gases flow area to the speed of
sound
Sound of Speed
speed Piston

d
x n
d
= Z
2
p
2
b
D
b
= cylinder bore dia.
D
p
= port dia.
n = number of ports
For mean values:
stroke RPM speed Piston
MEAN
= 2
)
`

Sound of Speed
stroke RPM

d
x n
d
= Z
2
p
2
b
2
For instantaneous relationships:
c
1
Sound of Speed
) (2
4L
s
+
2
s

60
2
RPM

d
x n
d
=
Z
d
2
p
2
b
i
(

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u u
t
Sin Sin
s = length of stroke L = length of connecting rod
= crank position C
d
= flow coefficient
Port Sizing and Mach Index (Z)
Speed of Sound:
Temperature and F/A ratio dependant
At Standard Temperature and Pressure

c = 1100 ft/sec
c = 340 m/sec
R
T 49.02 =
c
o
ft/ sec
K
T 20.05 =
c
o
m/ sec
Port Sizing and Mach Index (Z)
Modern performance engines will use multiple inlet and
exhaust valves per cylinder.
Many are using multiple intake runners per cylinder to
improve cylinder filling over a broader range of RPM.
A single runner is used at lower RPM while a second runner will
be opened at higher RPM.
The second and the combined each have their own tuning peak.
Port Sizing and Mach Index (Z)
Inlet Air Density and Performance
Inlet air density
Law of Partial Pressures:


If each is considered as a perfect gas

t
i air fuel vap water vap
P = Partial Pressures
P = P + P + P

P =
Mass
Molecular wt.
=
M
m
Inlet air density
Inlet Pressures and Densities:
m
/
M
+
m
/
M
+
m
/
M
m
/
M
=
P
+
P
+
P
P
=
P
P
w w f f a a
a a
water fuel air
air
inlet
air
m
a
= 29 m
w
= 18 m
gas
= 113
F
c
= chemically correct mix
F
i
= % vaporized (F
c
)
Inlet air density
Inlet Pressures and Densities:





From Ideal Gas Law
a
i
a
a f f w w
a
i i f
P
P
=
M / 29
M / 29 + M / m + M / m

P
P
=
1
1 + F (29 / m ) + h(1.6)
T
x R
P
x 29
=
T x R
p x m
=
i
a
a

R = 1545 ft-lb/(lbm-mole-
o
R)
Inlet air density
Inlet Densities:

a
i
i i f
=
29 x P
R x T

1
1 + F (29 / m ) + h(1.6)

(
T
x R
P
x 29
=
i
a
a

for P in psi
a
and T in
o
R
a
i
i i f
=
2.7 x P
T

1
1 + F (29 / m ) + h(1.6)

(
Inlet air density
Example Problem:
Find the change in indicated power when changing
from Gasoline to Natural Gas fuels
Assume: P
i
= 14.0 psia T
i
= 100oF
= 1.2 => 20 % Rich
h = 0.02 lb
m
/lb
m air

GASOLINE:
F/A = 1.2 x 1/14.8 = 0.081 lb
fuel
/lb
air

Assume fuel is 40% vaporized
(Use fuel distilation curves)
Inlet air density
Gasoline:



Natural gas:
F/A = 1.2 x 1/17.2 = 0.0697 lb
fuel
/lb
air

Fuel is a gaseous fuel and is 100% vaporized
mix
mix
m
3
=
2.7 x 14.0
460+100

1
1+(.4)(.081)(29 / 113)+0.02(1.6)
= 0.06488 lb /
ft

(
Inlet air density
NATURAL GAS:





mix
mix
m
3
=
2.7 x 14.0
460+100

1
1 + (1)(.06977)(29 / 18.3) + 0.02(1.6)
= 0.0591 lb /
ft

(
a
i
i i f
=
2.7 x P
T

1
1 + F (29 / m ) + h(1.6)

(
Inlet air density
NATURAL GAS:




INDICATED POWER RATIO:

mix
mix
m
3
=
2.7 x 14.0
460+100

1
1 + (1)(.06977)(29 / 18.3) + 0.02(1.6)
= 0.0591 lb /
ft

(
nat gas
gasoline
mix
c
c
c
Ihp
Ihp
=
x F / A x e
x F / A x e
nat gas
natgas
gasoline
gasoline

Inlet air density

Indicated power ratio:

nat gas
gasoline
mix
c
c
c
Ihp
Ihp
=
x F / A x e
x F / A x e
nat gas
natgas
gasoline
gasoline

nat gas
gasoline
Ihp
Ihp
=
0.0591 x 0.0697 x 21,800
0.06488 x 0.081 x 19,000
= .8993 90% ~
The above indicates an approximate 10% loss in power
output by changing to the gaseous fuel.
nat gas
gasoline
Ihp
Ihp
=
0.0591 x 0.0697 x 21,800
0.06488 x 0.081 x 19,000
= .8993 90% ~
Note: Gasoline performance decreases more rapidly
with increasing temperature.
Inlet air density
ACOUSTIC MODELING
Induction System Comparisons
Courtesy: Dan Butts, Derek Harris, Chris Brockman, Tiffany Dickinson
Closed Ended Organ Pipe:
Acoustic Modeling
Acoustic Modeling
Closed Ended Organ Pipe:



length effective = .3d + l = L
(Hz)
4L
c
= f
p
V x L
A

2
c
= f
H
t
Helmholtz Resonator:
V x L
A

2
c
= f
H
t
Acoustic Modeling
Build Considerations
Variable Length Runners for RPM
matching
Materials Selection Criteria:
Weight, Fabrication, Surface Finish,
Heat Isolation
Intake placement
Isolate from heat sources (Engine,
Exhaust, Radiator, Pavement)
Fuel Injector Placement
Courtesy: Dan Butts, Derek Harris, Chris Brockman, Tiffany Dickinson
Acoustic Modeling



Induction System Model
Multiple Stack with pressure box
Courtesy: Dan Butts, Derek Harris, Chris Brockman, Tiffany Dickinson
For a single degree of freedom system
Acoustic Modeling
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1 + CR
1 - CR
V L
A
x C x
K
=
N
d 1
1
1 p
A
1
= Average Area of Runner and Port L
1
= L
Port
+ L
runner

K
1
= 77 (English) K
1
= 642 (Metric)
C = Speed of Sound
Individual Throttle Body with Plenum
Courtesy: Dan Butts, Derek Harris, Chris Brockman, Tiffany Dickinson
Helmholtz Tuning
Writing Clearance Volume in Terms of Compression
Ratio:



The Primary Volume is considered to be the Cylinder
Volume with the Piston at mid-stroke (effective volume).
V
V
+
V
= CR
CC
CC S
1) - (CR
V
=
V
S
CC
1) - (CR
V
+
2
V
=
V
D D
P
1) - 2(CR
V
2 + 1) - (CR
V
=
V
D D
eff
1) - (CR
1) + (CR

2
V
=
V
D
eff
The tuning peak will occur when the natural Helmholtz
resonance of the cylinder and runner is about twice the
piston frequency.
Volume (V
1
) = Cylinder Volume
Volume (V
2
) = Volume in the path from V
1
to the Plenum
Using Engelman's electrical analogy we can define the
system as a system defined by capacitances and
inductances.
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A
L
= )
I
( Inductance
i
i
Helmholtz Tuning
The EFFECTIVE INDUCTANCE for a pipe with
different cross-sections may be defined as the sum of
inductances of each section.
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A
L
+ .... +
A
L
+
A
L
= )
I
(
n 1 + i i
e
The INDUCTANCE RATIO (a) is defined as the ratio of
the secondary inductance to the primary inductance.
Helmholtz Tuning
INDUCTANCE RATIO (a)




The CAPACITANCE RATIO (b) is defined as the ratio
of the Secondary Volume to the Primary Volume.
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A
L
A
L
= a
1
2
Helmholtz Tuning
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1 + CR
1 - CR
2 x
V
V
=
V
V
= b
D
2
eff
2
V
2
= Secondary Volume
= Volume of Intake Runners that are ineffective (n-1)
Calculate the Separate Inductances:





Determine the Inductance Ratio (a)
Helmholtz Tuning
A
L
=
I
port
port
port
A
L
=
I
runner
runner
runner
A
L
=
I
plenum
plenum
plenum
A
L
=
I
body T
body T
body T
.
.
.
I
+
I

I
+
I
A
L
A
L
= a
runner port
plenum body T
1
2
.
=
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Determine the Capacitance Ratio (b)



Determine the Induction system Resonances
V
x 1) - (n
V
= b
runner
eff
V
x ) (IND b a x 2
B - A

2
1
= f
eff
1
1
t
V
x ) (IND b a x 2
B + A

2
1
= f
eff
1
t
2
b a 4 - ) 1 + a + b (a = B 1) + a + b (a = A
2
Helmholtz Tuning
(IND)
1
= Inductance of the primary length
(IND)
1
= I
port
+ I
runner

Determine the Primary Resonance:


Determine the Frequency Ratios:


Determine the Tuning Peak:
Helmholtz Tuning
V
x
I
+
I
1

2
1
= f
eff
runner port
p
t
f
f
=
X

f
f
=
X
p
2
2
p
1
1
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1 + CR
1 - CR
V L
A
x C x
K
=
N
d 1
1
1 p
A
1
= Average Area of Runner and Port L
1
= L
Port
+ L
runner

K
1
= 77 (English) K
1
= 642 (Metric)
C = Speed of Sound
Intake Tuning Peaks become:
N
x
X
=
N
p 1 1
N
x
X
=
N
p 2 2
V
x ) (IND b a x 2
B - A

2
1
= f
eff
1
1
t
V
x ) (IND b a x 2
B + A

2
1
= f
eff
1
t
2 V
x
I
+
I
1

2
1
= f
eff
runner port
p
t
f
f
=
X

f
f
=
X
p
2
2
p
1
1
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1 + CR
1 - CR
V L
A
x C x
K
=
N
d 1
1
1 p
Helmholtz Tuning
A combined equation is possible indicating its 2
nd
order
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PV
4
1 + CR
1 - CR
V
V
2
eff
P
4 - 1 +
eff
P
+
1 + CR
1 - CR
V
V
2
eff
P
+
1 +
eff
P
+
1 + CR
1 - CR
V
V
2
eff
P
)
C
77( =
N
2
D
2
d
2
2
d
2
2
1
S 1,2
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A
L
= P
2
|
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A
L
= EFF
eff
1) - (NC *
A
* )
L
+
L
( =
V
m port man 2
* s
b
*
4
=
V
2
d
t
Helmholtz Tuning
David Visards Rule of thumb Equations


Using Visard's Equation for Runner Length
1. Starting point of 7 inches for 10,000 RPM
2. Add length of 1.7 inches for each 1000 RPM
less
Using Visard's Equation for Runner Diameter
The End
Thank You!