A. Project Title
Design and Comparative CFD Analysis of Intake Plenum for Formula Student Engine Using the DAI5 Framework
B. Author Complete Name
Muhammad Atha Zaidane Hamman NPM 2306155180
C. Affiliation
Department of Mechanical Engineering, Universitas Indonesia
D. Abstract
This report presents the design, simulation, and comparative evaluation of various intake plenum models for a twin-parallel cylinder Formula Student vehicle using the DAI5 engineering framework. The study explores the aerodynamic performance of several plenum geometries, emphasizing the dome-shaped design initially developed using Ricardo WAVE and ANSYS Fluent. Results indicate a 16.62% pressure drop and a mass flow rate of 0.866 kg/s, showing significant improvement over prior iterations. Additional comparative data from independent research conducted on variants like the “Fat-Man” design (6.49L volume) demonstrate improved air velocity (200 m/s) and reduced pressure drop (13,800 Pa). Previous models like UIRT-01 and Croissant design are also analyzed, showing pressure drops up to 40,000 Pa. CFD results are evaluated using turbulence intensity, mass flow symmetry, and resonance tuning. Literature from ResearchGate and ScienceDirect supports the relationship between plenum geometry, volumetric efficiency, and resonance behavior. The findings guide the development of a well-balanced, lightweight, and high-performance intake system tailored for Formula Student competition constraints.
E. Author Declaration
- Deep Awareness (of) I
Through this work, I remember The One and Only, acknowledging that the pursuit of engineering knowledge is a form of devotion. I recognize that design is not only a technical activity but a conscious responsibility to create beneficial and ethical solutions. I am aware of the trust placed in me as a creator and submit this project with humility and gratitude.
- Intention of the Project Activity
This project intends to optimize the intake airflow system to support higher volumetric efficiency, engine responsiveness, and performance for our Formula Student car. Rooted in the values of sustainability, integrity, and remembrance, the aim is to generate effective results through conscious design, simulation, and iterative development, aligned with ethical and practical goals.
F. Introduction
In Formula Student competitions, the performance of the air intake system plays a crucial role due to the implementation of a 20 mm restrictor, which limits the air entering the engine. Poor intake design can cause imbalances, pressure drops, and turbulence that reduce combustion efficiency and power output.
Initial evaluation of UIRT-01 (1.8L, 33,000 Pa drop) and later designs such as the Croissant (3.0 kPa pre-runner, 40 kPa with runner) and Proto-trapezoid (2.2L) revealed several inefficiencies. Zaahir’s study introduced larger volume and Helmholtz resonance considerations. Based on studies by Liu et al. (2006) and Gusri et al. (2015), plenum volume significantly influences flow rate and efficiency.
The initial thinking focuses on:
- Pressure recovery post-restrictor.
- Volume optimization (between 6x–10x engine displacement).
- Minimizing turbulence and vortex formation.
- Mass symmetry to both cylinders.
G. Methods & Procedures
Idealization
- Steady-state, compressible flow simulation using k-epsilon turbulence model.
- Ricardo WAVE used to determine runner length based on resonance.
- Helmholtz resonance equation to match runner length with valve timing.
Instruction Set
- CAD designed using SolidWorks and Inventor.
- Mesh generation and flow analysis using ANSYS Fluent.
- Comparison between:
- Dome-shaped (baseline)
- Fat-Man (6.49L)
- Train (2L), Vase (3.5L), Croissant, Zaahir 3.2L
- Metrics analyzed:
- Pressure drop
- Mass flow rate
- Velocity distribution
- Turbulence and eddy viscosity
- Plenum-to-runner symmetry
H. Results & Discussion
1. Dome-Shaped Plenum (Baseline)
- Volume: not specified explicitly, early design.
- Results:
- Mass Flow Rate: 0.866 kg/s
- Pressure Drop: 16.62%
- Velocity: Mach 0.37
- Pros: Good symmetry, simple design.
- Cons: Less responsive at low RPM.
2. Fat-Man Plenum (Naufal)
- Volume: 6.49 L
- Runner Length: 193 mm
- Results:
- Velocity: 200 m/s
- Pressure Drop: 13.8 kPa
- Pros: Best airflow symmetry, high VE.
- Cons: Large volume, potential packaging challenges.
3. Zaahir Design
- Volume: 3.2 L
- Runner Length: 100 mm
- Inlet Velocity: 350 m/s
- Results:
- Max Velocity: 750 m/s
- Pressure Drop: 32,000–68,000 Pa (depending on setup)
- Pros: Responsive design with Helmholtz tuning.
- Cons: Highly dependent on configuration.
4. Croissant Plenum
- Velocity: 367 m/s (no runner), 40,000 Pa drop (with runner)
- Pros: Initially promising
- Cons: Failed geometry compliance, vortex issues
5. Train, Vase, Proto-trapezoid
- Volumes: Train 2L, Vase 3.5L, Proto 2.2L
- Mixed results, none reached performance target
I. Conclusion, Closing Remarks, Recommendations
Among all designs, the Fat-Man model provides the best balance of air velocity, pressure drop, and manufacturability. The use of resonance principles and CFD validation proved effective. Future work should validate through dyno testing and flow bench measurement. Use of carbon fiber composites can further reduce weight.
J. Acknowledgments
Thanks to the UIRT Engine Division, mentors, CFD team, and contributors to each intake design version. Special mention to internship contributors and technical support from Ricardo WAVE and ANSYS simulation teams.
K. References
- ANSYS Fluent Theory Guide.
- Ricardo WAVE Simulation Manual.
- Heywood, J.B., Internal Combustion Engine Fundamentals, McGraw-Hill.
- Liu, Y., et al. (2006). Effect of intake system design on engine performance using CFD simulation. Energy Conversion and Management.
- Gusri, A.I., et al. (2015). CFD analysis of the air intake system. Procedia Engineering.
- Yazdani, M. et al. (2014). One-Dimensional Engine Modeling Using Ricardo WAVE. ResearchGate.
- Kong, S.C., et al. (2010). Intake port geometry effects using CFD. Energy Conversion and Management.
- UIRT Final Design Report – Intake System.
- Naufal R. (2024). DESIGN REPORT Intake Plenum. UIRT.
- Zaahir F. (2023). FINAL Plenum Report. UIRT.
L. Appendices
- Appendix A: Geometry of Each Design Iteration
- Appendix B: Meshing and Simulation Parameters
- Appendix C: Runner Length Calculation Sheets
- Appendix D: CFD Visualization – Pressure, Velocity, Streamlines (see figures below)
