Intake Manifold Stress Analysis and Performance Test

To start 3D design - benchmark with various designs used in past for shape and size. Because 1 D simulation in GT, Ricardo, Lotus etc give spec and not shape. Check previous blogs to understanding modeling in 1D. As it is design phase, we will make proto part only - i.e only few intake manifold will be made so ADC12 is best. Plastic moulding machine is very costly so amortization is not possible for prototype part.  On these few component physical part level testing will be done as explained in end of this blog. After successfully completing these physical tests, further optimization in intake manifold design will be done.  

In-Manifold 3D was made in solid work considering 2.8 Liter Volume and 260 mm runner length with 35 mm circular Dia. This is basic primary shape to start 3D Analysis. 

Strength Simulation:-

For above made CAD 3D, ADC 12 properties used for strength analysis. Meshing parameters are shown in table. ADC12 is best because we can make it by sand casting which is very low cost. After sand casting machining will be done to achieve surface finish, GDNT and roughness etc. Plastic or PA66GF35 can be used but plastic moulding machine machine is very costly. 

Mesh type	Solid Mesh
Mesher Used:	Standard mesh
Jacobian points	4 Points
Element Size	10.3939 mm
Tolerance	0.519694 mm
Mesh Quality	High

Conclusion from above Graph:-

To reduce weight runner thickness can be reduced as stress is less in runner. To reduce stress on diffuser mounting place, thickness of this surface will be increased.

Intake Manifold Part Level Testing

Performance Test for Intake Manifold 

1-Air Tightness of Plenum and Runner

Plug All Runners and Injector Hole. Apply -20 Bar Vacuum from Air Inlet Hole

Maximum Pressure Drop 0.6 KPa. Compare before and after test part dimension.

2-Injector Sitting Area Test 

Assembly Rail and Injector On In-Mani. Apply 30 Bar Pressure from Rail.

No Fuel Leakage should occur from both O side of Injector.

3-Vibration Test

Fix In-Mani on Fixture. Apply 30g Vibration in X,Y and Z direction for 500 Hours.

Do Test Number 1 and 2.

4-Thermal Test

Keep Intake Manifold at 200 °C for 500 Hour.

Do Test Number 1 and 2.

5- Engine Level Test and Vehicle Level Test  

Vehicle Calibration, Engine Calibration, Engine Durability and Vehicle Durability

After Test, dismantle intake and do Test Number 1 and 2.

Please check previous articles for Intake Manifold Layout, DFMEA, Plenum Volume, Runner Length and Cross Section, 1 D Simulation analysis from scratch and also Intake Noise Study, Resonator retirement study, Positioning on MAP Sensor on Intake Manifold etc.