APPROVAL
“I hereby declare that I have read this thesis and in my opinion this thesis is sufficient in
term of scope and quality for the award of Bachelor of Mechanical Engineering (Design
& innovation)”
Signature
: ………
THE DESIGN AND DEVELOPMENT OF
ENGINE INTAKE MANIFOLD FOR PROTON WIRA
MOHD AFDHAL BIN SHAMSUDIN
This report is submitted as partial fulfillment of the requirement for the award of
Bachelor of Mechanical Engineering (Design & Innovation)
The Faculty of Mechanical Engineering
Universiti Teknikal Malaysia Melaka
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DECLARATION
“I hereby, declare this thesis is result of my own research except as cited in the references”
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DEDICATION
Highest Special Thanks to Both Father and Mother
Shamsudin Bin Abu Samah &
Norsidah Bte Shamsudin
also
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ACKNOWLEDGEMENT
First of all, I would like to thanks Gods that have given me the opportunity to complete my ‘Project Sarjana Muda’ (PSM). I worked hard in completing this project within a semester.
Next, I would like to thanks to my supervisor, En Shafizal bin Mat, who is willing to offer his support throughout my final year project. He has supported me in the best way in finding the information about my project. He is also very kind to contribute his time, patience, and guidance in helping me completing my project. His experience in this related topic is so valuable in my case study.
I would like to express my utmost gratitude to all my friends, regardless they are in UTeM or outside of UTeM for supporting and helping me in making this project success. The information, assistance, and help are so useful to me until the final stage of my project.
Not forgetting to say, lot of thanks to UTeM lab technical assistants En. Muzaini Bin Sahary and technician, En. Mohd Kamil Anuar Bin Akram for their co-operation in lab tools usage. Thanks also to UTeM librarians and staff for their information and assistance regarding UTeM’s facilities and resources. Warm thank you also goes to language department staff especially Ms. Noraini Bt Husin for co-operation in editing the language in this report.
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I am willing to a say highest special thanks word to my lovely family, Shamsudin Bin Abu Samah, Norsidah Bte Shamsudin and my beloved brothers and sister. I don’t know how to say my thankfulness to them. The encouragement and the spending money in buying everything that related to complete my project is most valuable to me. Without them I think I can’t complete my project. Alhamdulillah.
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ABSTRAK
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ABSTRACT
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CHAPTER TOPICS PAGE
2.3 Flow In Pipe 17
2.4 Compressible and Incompressible Flow 18 2.5 Automotive Mass Airflow Sensors 19 2.6 Case Study of Existing Product 20
2.7 Intake Manifold Material 35
2.8 SolidWorks Software 37
2.9 Computational fluid dynamics (CFD) 38
2.10 Finite Element Method 40
2.11 CosmosWorks Designer 41
2.12 Plastic in Intake Manifold 42
3.0 METHODOLOGY 45
3.1 Introduction 45
3.2 Case Study 48
3.3 Real Product of Existing Intake Manifold 49
3.4 SolidWorks 50
3.5 Create 3D Drawing 53
3.6 Computational Fluid Dynamics (CFD) 58
3.7 Cosmosflowork Analysis 59
3.8 Design Analysis 63
3.9 Existing Product Drawing 63
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CHAPTER TOPICS PAGE
3.15 Detail Drawing of Proposed 6 design 73
3.16 Methodology Flow Chart 75
4.0 RESULTS AND DISCUSSION 77
4.1 Introduction 77
4.2 Cosmosflowork 78
4.3 Cosmosflowork Input and Result 80
4.3.1 Existing Design Result 81
4.3.2 Proposed 1 Design Result 82 4.3.3 Proposed 2 Design Result 84 4.3.4 Proposed 4 Design Result 85 4.3.5 Proposed 5 Design Result 87 4.3.6 Proposed 6 Design Result 89 4.3.7 Result for Proposed 6 Design Using Plastic 91
4.4 Discussion 93
4.5 Material Discussion 99
5.0 CONCLUSION AND RECOMMENDATION 102
5.1 Conclusion 102
5.1 Recommendation for future works 103
REFERENCES 105
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LIST OF FIGURES
NO. TITLE PAGE
Figure 2.1 Sample of Engine 9
Figure 2.2 Diesel engine air system 11
Figure 2.3 Sample of intake system part 12
Figure 2.4 Sample of throttle body 12
Figure 2.5 Throttle Body For Proton Wira 1.6 XLi 14 Figure 2.6 Air Filter for Proton Wira 1.6 XLi 1 15 Figure 2.7 Air Filter for Proton Wira 1.6 XLi 2 15 Figure 2.8 Air Filter location for Proton Wira 1.6 XLi 16
Figure 2.9 Sample air flow 17
Figure 2.10 Intake manifold Proton Wira 1.6 XLi 20 Figure 2.11 Modular inlet manifold for investigating dynamic manifold
and valve characteristic 22
Figure 2.12 Effect of volume of plenum chamber on variation of volumetric efficiency with engine speed for four-cylinder
engine 24
Figure 2.13 Plenum of Intake Manifold Proton Wira 1.6 XLi 25 Figure 2.14 Effect of length of secondary pipe on variation of volumetric
efficiency with engine speed for four-cylinder engine 26 Figure 2.15 Effect of area of secondary pipe on variation of volumetric
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NO. TITLE PAGE
Figure 2.17 Location of Secondary for Pipe Proton Wira 1.6 XLi Intake
System 28
Figure 2.18 Effect of length of primary pipe on variation of volumetric
efficiency with engine speed for four-cylinder engine 30 Figure 2.19 Effect of length of primary pipe on variation of volumetric
efficiency with engine speed for four-cylinder engine 30 Figure 2.20 Effect of area of primary pipe on variation of volumetric
efficiency with engine speed for four-cylinder engine 31 Figure 2.21 Comparison of volumetric efficiency curves for a four-cylinder
engine fitted with open primary pipes and a simple rake manifold 32 Figure 2.22 Primary Pipe for Proton Wira 1.6 XLi Intake Manifold 33 Figure 2.23 Fuel Injector Hole for Proton Wira 1.6 XLi Intake Manifold 34 Figure 2.24 Air Return Pipe for Proton Wira 1.6 XLi Intake Manifold 35 Figure 2.25 Air flow around a jet fighter design illustrating the application
of CFD to areas previously the province of wind tunnel testing 39 Figure 2.26 A computer simulation of high velocity air flow around the
Space Shuttle during re-entry 39
Figure 2.27 Material properties for plastic Pa Type 6 (Polymide-15%
Glass Fibre). 44
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NO. TITLE PAGE
Figure 3.13 Front view of proposed 2 design with dimension 70 Figure 3.14 Side view of proposed 4 design with dimension 71 Figure 3.15 Front view of proposed 4 design with dimension 71 Figure 3.16 Side view of proposed 5 design with dimension 72 Figure 3.17 Front view of proposed 5 design with dimension 73 Figure 3.18 Side view of proposed 6 design with dimension 73 Figure 3.19 Front view of proposed 6 design with dimension 74
Figure 3.20 Flow Chart of the methodology 76
Figure 4.1 Velocity scale 79
Figure 4.2 Existing Design Flow Pattern (Velocity parameter) 81 Figure 4.3 Sample of pressure result value (Existing design) 81 Figure 4.4 Proposed 1 Design Flow Pattern (Velocity parameter) 82 Figure 4.5 Sample of velocity result value (Proposed 1 design) 83 Figure 4.6 Proposed 2 Design Flow Pattern (Velocity parameter) 84 Figure 4.7 Sample of pressure result value (proposed 2 design) 84 Figure 4.8 Proposed 4 Design Flow Pattern (Velocity parameter) 85 Figure 4.9 Sample of velocity result value (proposed 4 design) 86 Figure 4.10 Proposed 5 Design Flow Pattern (Velocity parameter) 87 Figure 4.11 Sample of velocity result value (proposed 5 design) 88 Figure 4.12 Proposed 6 Design Flow Pattern (Velocity parameter) 89 Figure 4.13 Sample of velocity result value (proposed 6 design) 89 Figure 4.14 Proposed 6 Design Flow Pattern (Velocity parameter) 91 Figure 4.15 Sample of velocity result value (proposed 6 design) 91 Figure 4.16 Pressure analysis for PA Type 6-15% material (proposed
6 design) - minimum 100
Figure 4.17 Pressure analysis for PA Type 6-15% material (proposed
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LIST OF TABLE
NO. TITLE PAGE
Table 2.1 Real Picture Of Each Part For Existing Intake Manifold 20 Table 2.2 Parameter of Intake Manifold Proton Wira 1.6 XLi 22 Table 2.3 Parameter for example experiment engine 32 Table 2.4 Aluminium [Alloy 1100-H14 (99% Al)] Properties 36
Table 3.1 SolidWorks Command 1 51
Table 3.2 SolidWorks Command 2 52
Table 3.3 SolidWorks Command 3 52
Table 3.4 SolidWorks Step 54
Table 3.5 Cosmosflowork Step 60
Table 4.1 List of parameter result value of existing design 82 Table 4.2 Table of parameter result value of proposed 1 design 83 Table 4.3 Table of parameter result value of proposed 2 design 85 Table 4.4 Table of parameter result value of proposed 4 design 86 Table 4.5 Table of parameter result value of proposed 5 design 88 Table 4.6 Table of parameter result value of proposed 6 design 90 Table 4.7 Table of parameter result value of proposed 6 design 92 Table 4.8 Comparing between existing design and proposed 6 design 93 Table 4.9 Comparing between existing design and propose 6 design
(cut plots) 98
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LIST OF SYMBOLS
A = Cross section area, mm2
ρ = Density, kgm-3
= Mass Flow Rate, kg/s
Q = Volume Flow Rate m3/s
V = Volume, m3
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LIST OF APPENDICES
NO. TITLE PAGE
A PSM I and PSM II Gantt Chart 107
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CHAPTER I
INTRODUCTION
1.1 Background Study
Engine is the most important part in one vehicle. M.F. Harrison, et. al., (2003) said, the intake manifold to an internal combustion (IC) engine will consist of a network of interconnecting pipes. The lengths of these pipes, and to a certain extent their diameters, must be chosen carefully as they will determine the resonant frequencies of the manifold. When the engine is run at a speed where one or more of these resonances is excited, then both the volumetric efficiency and the intake noise level maybe affected.
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DE Winterbone et. al., (1999) also said, two-stroke engines, which do not have discrete suction and exhaust strokes, rely almost entirely on the operation of the exhaust gas dynamics to purge the cylinder of combustion products and the manifolds of these engines have a dramatic effect on their performance. In order to achieve higher specific power outputs (power/swept volume) some engines have induction systems in which the supply pressure of the air to the engine is increased above the ambient level by some form of supercharging system. This increase the quantity of air ingested per engine cycle. Successful design of the exhaust system in turbocharged engines helps ensure that sufficient energy is available at the turbine, over the operating spectrum of the engine, to drive the compressor at a condition spectrum of the engine, to drive the compressor at a condition which will produce the required boost ratio.
The requirement for lower noise and pollutant emissions levels has further increased the important of the design of the intake and exhaust manifolds. A large proportion of the total noise generated by vehicle and stationary engines is due to the pressure waves issuing from them as noise.
The position of intake manifold is normally located at behind of engine block. At this time, there are so many materials that used in making the intake manifold. All of those materials are used based on the specific purpose following the usage of that vehicle which applies that type of engine.
This material will also effect the output performance of intake manifold. Normally, intake manifold is created and studied by engineering field to reduce pressure wave amplitude and to act on specific component frequency.
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seat concept. This model is then expends its version by launching Limousine version which focuses on high class usage and luxurious concept. After a period of time, diesel model of Wira is introduced to fulfill the customer demands. Internal and external design level for all model is improved and in early 1996,’New Look Wira’ is launched. Emergence of new version Wira 1.8 EXi is completing the various versions among existing Wira model.
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1.2 Problem Statement
There are many problems with the existing intake manifold design, such as it cannot give the best pattern of air flow induction in trying to have the best performance of engine. This is because of the main function of intake manifold is to flow the air into engine block (engine cylinder) and direct it to induction valve at top of cylinder head.
It has long been realized that the design of inlet manifolds has a large effect on the performance of reciprocating engines. This project is focused on intake manifolds design and it material properties. Design of intake manifolds has lot of effect to engine performance, temperature on inlet valve and smooth of flow. Stability of engine working is also involved in the design of intake manifold. That means rate of rotation per minute (RPM) for valve is depend on intake manifold design and also throttle body system.
Problems that will be studied in this project are:
1. Effect of curve pattern of primary pipe 2. Effect of material on intake manifold
The unsteady nature of the induction processes means that the effect of the manifold on charging and discharging is extremely dependent upon the engines speed. This is because the impedence (or admitance) of the manifold is a function of the frequency of the pulses entering it. The outcome of this is that it is possible to tune engine manifolds to give a particular power output characteristic as a function of speed.
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1.3 Project Objective
The main objective of this project is to learn and understand the concept and working principles of intake manifolds component for any model car and Proton Wira model. Type of component that involves in intake manifold part, component of car intake system, effect of intake manifold design and material will be studied through literature review. Journals and books will be the main sources of getting the information.
The study is also referring to existing product of intake manifold in market. The design of existing intake manifolds is adapted to CAD software. Effect of velocity, temperature and materials will be analyzed through CFD software based on existing design.
The new design and material will be proposed as purpose to improve the output performance in term of velocity, temperature and materials effect. The design and material that proposed is base on studying that done before. CFD and FEM technique will be used to make a computational analysis for proposed intake manifold design.
Objectives of this project are:
1. To understand the working principles, components, design and development of the intake manifold through literature study.
2. To analyze existing design of intake manifolds for Proton Wira/Waja and its material properties.
3. To propose new design and material of intake manifold.
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1.4 Project Scope
This project is base on Proton Wira car intake manifold. Scope of this project is to cover case study through the literature review and journal for existing and other car intake manifold. From this study, characteristics of intake manifold is learned.
This scope of study includes the way of using the SolidWorks software in adaptation the existing intake manifold design into that software. The new design concept and material will be proposed using this software. This is also base on the literature review in improving the output from this intake manifold system.
CFD software is also included in scopes of this project. CFD software is used to analyze existing and new design of intake manifold. Comparison will be done in finding the best design and material of intake manifold. Final design and justification will be made at the final level of this project.
Scopes of this project are:
1. Literature review on the existing design of intake manifolds 2. Study the characteristic of existing and others car intake manifolds
3. Construct the 3D model of the existing product using SolidWorks software 4. Perform CFD analysis of the existing intake manifold
5. Propose new design and material of the intake manifold base on the analysis done
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CHAPTER II
LITERATURE REVIEW
2.1 Introduction
Combustion is one of the chemical reactions that always happen in round world. In that chemical reaction process, oxygen gas normally use in helping combustion process for merge with other element like hydrogen or carbon.
The same combustion is happen in engine. Rosli Hussin, (1996) in his book said, air and fuel (in the steam form) mixed in engine for compressed and fired. Oxygen gases that available in air is taken from atmosphere. 21 % from air content is oxygen. Gasoline is compound those mentioned hydrocarbon because it containing lot of element of carbon and hydrogen. When the gasoline burnt in engine, it to be decomposed becomes carbon and hydrogen. Both elements is combine with oxygen from the air. Carbon is combining with oxygen than formed carbon monoxide (COx) in the gas form while hydrogen is combining with oxygen and forming water (H2O) that came out from the engine in steam form.
