Study On Design Of DA5 Engine Plastic Intake Manifold

In recent years, the high efficiency of the engine, reducing fuel consumption, improve performance and reduce exhaust emissions have become increasingly demanding circumstances, the conventional engine design concepts are constantly being updated. As to the engine performance and fuel consumption, etc is one of the important link of the enormous influence: the engine intake system, particularly the intake manifold design requirements are continuously improving, some highly integrated, structure shape complicated plastic intake manifold been widely used.Plastic intake manifold wall is smooth, can reduce air resistance, the more easily designed according to the engine performance needs of complex structure shape, can improve performance needs of complex structure shape, can improve performance, improve efficiency and engine emissions, and plastic intake manifold light weight, materials and manufacturing cost low. The plastic intake manifold is already a global trend. Based on the DongAn DA5 engine project for background, carry on plastic intake manifold design research on 1.3-1.5L engine.First intake of the engine exchange process conducted in-depth research, focus on the intake and exhaust dynamic effects of the port, the air flow energy loss of intake system. The intake manifold overall design ideas are proposed.Use AVL BOOST one-dimensional thermal dynamic simulation analysis software, the factors affecting the engine performance simulated calculation and analysis, analysis the intake manifold structural parameters on the engine performance, the effect of analysis and engine other structural parameters change interaction effects. In both the 1.3-1.5L DOHC FF and FR engine plastic intake manifold overall structure layout, the assembly and manufacturing technology is analyzed.Use of AVL 3d CFD software conducted the plastic intake manifold flow analysis, analysis of each cylinder intake consistency and intake manifold internal pressure loss. Using the universal finite element software structure strength analysis of manifold inlet manifold structure strength, modal and noise is analyzed and calculated. These calculations for the intake manifold provide theoretical basis for 3d structure optimization.Using the 1.3L plastic intake manifold engineering prototype on engine test bench test, investigate manifold on each cylinder pressure and temperature in distribution, and engine performance and fuel consumption. Experimental data shows that the intake uniformity of each cylinder is good, different condition, each port the intake pressure almost no deviation. Engine performance meets the developing goal. Part load fuel consumption compared with competitive models performs well, can reach engineering target.By the theory and practice, this paper for the DA5 engine development project meet the target provides technical support and follow-up project for the engine of the intake system design to provide technical reserves.