Air Intake Manifold Research Articles

Coupling of flow simulation and structural analysis for glass‐filled thermoplastics

AbstractIn the automotive industry, glass‐filled thermoplastics are used in air intake manifolds, radiator tanks, and many other parts. Plastic parts have many advantages over metal parts including mass, design flexibility and parts consolidation. However, widespread application of glass‐filled thermoplastic materials has been limited in many cases by the inability to accurately predict performance and durability. Fiber‐filled injection‐molded parts contain complex fiber orientation patterns. This fiber orientation state affects material properties including elastic modulus and strength and part properties including shrinkage and warpage. Tremendous amounts of time and money can be saved if one can predict the moldability and mechanical properties of a part at the design stage. In this work, we present a method where commercially available injection molding and structural analysis software may be coupled together with appropriate material property data to improve prediction of structural performance for parts molded from short glass fiber‐filled plastics. In addition, we compare the experimental and predicted performance based on simple equations and complex finite element calculations. Two major conclusions may be drawn from this work. In general, the assumption of geometric nonlinearity must be made. Also, an orthotropic material model is generally more robust and accurate than an isotropic analysis. Polym. Compos. 25:343–354, 2004. © 2004 Society of Plastics Engineers.

Vibration welding air intake manifolds from reinforced nylon 66, nylon 6 and polypropylene

Vibration welding is a common method for creating complex hollow parts from simpler injection molded components. This work studied the vibration welding of an industrial air intake manifold (AIM) made from nylon 66, nylon 6 and polypropylene all reinforced with 30% glass fibres. The meltdown-time profiles were measured and compared to those of simple lab-scale butt-weld assemblies. The experimental results indicated that the meltdown rate of the manifold was controlled by the slower rate of transverse welding. The burst strengths of these AIM at various welding conditions were also investigated. Results of finite element analysis indicated that the highest von Mises stresses and the maximum normal principle stresses at the weld region of the AIM were comparable to the weld strength of corresponding lab-scale coupons, confirming that the initial failure occurred in the weld region.

Low permeation sealing of air intake manifolds

Automotive design engineers are now forced to take a hard look at losses from air intake manifold systems and engine oil gaskets. This feature looks at some of the issues they face when sealing such components, and it explains how DuPont Dow Elastomers’ Viton AL fluoroelastomer is helping them to achieve their goal.

Elucidating complex design and management tradeoffs through life cycle design: air intake manifold demonstration project

The life cycle design (LCD) framework for enhancing design analysis and decision making is demonstrated through a collaborative effort between the University of Michigan, a cross functional team at Ford, and the US Environmental Protection Agency. The LCD framework was used to evaluate three air intake manifold designs: a sand cast aluminum, brazed aluminum tubular, and nylon composite. Life cycle inventory, life cycle cost and product/process performance analyses highlighted significant tradeoffs among alternative manifolds, with respect to system design requirements. The life cycle inventory indicated that the sand-cast aluminum manifold consumed the most life cycle energy (1798 MJ) compared to the tubular brazed aluminum (1131 MJ) and nylon composite (928 MJ) manifolds. The cast aluminum manifold generated the least life cycle solid waste of 218 kg per manifold, whereas the brazed aluminum tubular and nylon composite manifolds generated comparable quantities of 418 kg and 391 kg, respectively. Material production accounted for 70% of the total life cycle solid waste for the brazed tubular manifold, while auto shredder residue was responsible for half the total waste for the nylon composite design. The life cycle cost analysis estimated Ford manufacturing costs, customer gasoline costs, and end-of-life management costs. The nylon composite manifold had the highest estimated manufacturing costs but the least use phase gasoline costs. Significant end-of-life management revenues from aluminum recycling would accrue to Ford under automobile take back legislation. A total of 20 performance requirements were used to evaluate each design alternative.

Technyl provides high stiffness and rigidity for air intake manifold

Technyl provides high stiffness and rigidity for air intake manifold

High performance polyamides

Especially for heavy-duty applications such as air intake manifolds and valve and engine covers, high performance polyamides have now become available that will last significantly longer than conventional resins. Due to a new combination of stabilizing additives, they can now achieve lifetimes of 3,000 hours at 150°C.

Trimming in a Snap

This article emphasizes on the use of thermoplastics in engines. One case in point is a reinforced nylon multifunctional module involving three components—air intake manifold, cam cover, and design cover-on the Alfa Romeo 156 engine. The project was a collaboration of Rhodia Engineering Plastics of France, Robert Bosch GmbH of Germany, and Magneti Marelli S.p.A. of Italy, system supplier for Fiat, which manufactures the Alfa Romeo. The article also shows an example where an under-the-hood reinforced nylon module on the Alfa Romeo 156 engine saved weight, allowed part integration, and incorporated a snap-fit assembly technique. According to an expert, the nylon also made possible more efficient assembly techniques. The air intake manifold, for example, is assembled using snap-fits, eliminating the need for welding or screw. The part provides high dimensional stability, good heat distortion temperature, and resistance to oils.

Identification and idle speed control of internal combustion engines

This paper presents an integrated approach for the identification and control of internal combustion engines in idle-speed conditions. The inputs of the nonlinear identification model are the position of the idle speed air actuation system and the spark advance, while its outputs are the pressure inside the air intake manifold and the crank shaft speed. The estimated model is then used to synthesize an idle speed controller with the linear quadratic technique. The design procedure outlined here is currently being used by Magneti Marelli for the synthesis of commercial idle-speed regulators. Some identification and control results obtained by applying this method to a 1400 cm 3 commercial engine are reported to witness the effectiveness of the proposed approach.

チューブタイプエアインテークマニホールド（ＡＩＭ）の開発と実用化

チューブタイプエアインテークマニホールド（ＡＩＭ）の開発と実用化

ろう付け性を有するアルミニウム合金鋳物製フランジの開発

In the development of flange made by an aluminum alloy casting for an air intake manifold (AIM) of a car, Al-Zn-Mg, Al-Mn-Mg, Al-Mg and Al-Mg-Si alloys were investigated on their casting properties, strength and brazability with A6063 alloy extrusion tubes. The alloy for the flange was required to have a solidus temperature higher than that of A4045 alloy and to have Mg content less than 0.6 mass%. Consequently, 712.0 alloy, which was inferior to Al-6Si alloy in casting properties but strong enough after the exposure to the brazing temperature, was chosen as the most suitable alloy for the flange. The casting design without defects was also studied using this alloy. Based on the fact that shrinkages were located in the part where G/√R_??_0.5 (G: the gradient of temperature, R: the cooling rate), the production of the casting flange without defects has been achieved by a high and long neck in the riser of the sand mold.

Fatigue properties of brazed aluminum alloy joints.

The fatigue life distribution of the brazing butt joint consisted of D712.0 and A6063 alloys were analyzed statistically, in order to evaluate reliability and strength characteristics of air intake manifold (AIM) made by brazing joint of cast and wrought aluminum alloys. Obtained results are summarized as follows;(1) Fatigue life distribution of the brazing joint is scattered according to the normal distribution.(2) Scatter of fatigue life seems to be influenced by brazing defect ratio, filler metal microstructure and joint force with base metals.