UWE Bristol Engineering showcase 2015

Kris Penney
BEng Motorsport Engineering
Project Supervisor
Dr. Changho Yang
Inline Four Cylinder Turbocharged SI Engine Exhaust Manifold Design
with Toyota 4EFTE Engine Case Study
Exhaust Manifold Design Research
Research into turbocharged exhaust manifold
design and naturally aspirated exhaust manifold
design as many important factors in this field cross
over to turbocharged design
Data Gathering of Initial Parameters
Measurements of the standard exhaust manifold
geometry were taken. It was also necessary to
deduce certain areas of the engine geometry
including the inlet and exhaust camshaft profiles,
exhaust port geometry, valve dimensions, valve
timing data and cylinder dimensions. From this
information a good understanding of the gas
exchange process behaviour can be gained. This
data also assisted in accurate engine simulation to
gain as valid results as possible.
Valve Lift (mm)
Flow Bench Testing
By using the Universities SF-110 Superflow flow bench, further knowledge was gained regarding the flow
rates and restrictions of the cylinder head and standard exhaust manifold which could be compared with
the figures obtained for the new manifold designs. Experimental data was also used to achieve further
accuracy in engine simulation.
8
7
6
5
4
3
2
1
0
4EFTE Standard Camshaft Profiles and Timing
0 180 360 540 720
Crankshaft Angle (deg)
CFD Analysis
The flow behaviour through the new manifold designs was analysed using
CFD flow simulation, looking for any aspects that may impede flow. The
types of flow included constant flow simulation of flow bench testing of
the new designs, in addition to transient flow simulation to analyse the
time dependant periodic gas flow from the engine cylinders
Exhaust
Inlet
Project summary
Research and analysis has been carried out to
understand 4 cylinder turbocharged IC engine
exhaust manifold design, investigating the individual
topic areas where analysis can lead to the
improvement of engine performance and efficiency.
The Toyota 4EFTE engine was used as a case study.
Project Objectives
• Research into existing exhaust manifold design
techniques.
• Flow bench testing to understand and utilise the
flow characteristics of the cylinder head and
standard exhaust manifold.
• Produce three 3D CAD models of different design.
• Computational fluid dynamics (CFD) analysis to
understanding the benefits and drawbacks of each
design.
• 1D engine simulation to examine the influence of
the three improved manifold designs on the
engine performance as compared with the
standard manifold as well as each other.
• Finite Element Analysis (FEA) to understand the
strength properties of the three designs .
• Examine all results and draw conclusions as to
optimal design technique.
3D CAD Modelling of Manifold
Designs
CAD models were constructed for
three exhaust manifolds. All three
have the same pipe volumes with
changes made to pipe diameter and
length
FEA Analysis
An FEA study was carried out on the three manifold design CAD models to
analyse the levels of stress, strain and deflection experienced by each design.
1D Engine Simulation
Once the design was finalised, it was necessary to
investigate how the new manifolds affect the performance
of the engine when compared to the standard manifold
and each other.
1D engine simulation was used which allows for the
engine parameters to be configured into a simulation. This
simulation was set up with key data from both the new
and existing manifolds to give comparative information
regarding the engines performance
Project Conclusion
It was shown that considerable gains in engine
efficiency and performance can be made through
improvement of the exhaust system.
Maximum % increase in brake power was seen to be
22.5% and 2.4% increase in brake torque when the
4EFTE standard manifold was replaced with an
optimised design.
The analysis also showed that it is possible to
manipulate engine performance characteristics to
suit specific engine requirements.