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Intake Port Flow Study on Various Cylinder Head Using Flowbench

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Intake Port Flow Study on Various Cylinder Head Using Flowbench INTAKE PORT FLOW STUDY ON VARIOUS CYLINDER HEAD USING FLOWBENCH MOHD TAUFIK BIN ABD KADIR UNIVERSITI MALAYSIA PAHANG INTAKE PORT FLOW STUDY ON VARIOUS CYLINDER HEAD USING FLOWBENCH MOHD TAUFIK BIN ABD KADIR A report is submitted in partial fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Engineering with Automotive Engineering Faculty of Mechanical Engineering Universiti Malaysia Pahang NOVEMBER 2008 SUPERVISOR DECLARATION We hereby declare that we have checked this project and in our opinion this project is satisfactory in terms of scope and quality for the award of the degree of Bachelor of Mechanical Engineering with Automotive Engineering. Signature : Name of Supervisor: Mr. Fairusham Position: Date: Signature: Name of Panel: Position: Date: STUDENT DECLARATION I declare that this thesis entitled “Intake Port Flow Study on Various Cylinder Head Using Flowbench” is the result of my own research except as cited in the reference. The thesis has not been accepted for any degree and is not concurrently submitted in candidature of any other degree. Signature : .............................................. Name : Mohd Taufik Bin Abd Kadir Date : ……………………………. Dedicated to my beloved Parents and Family, Especially to my late Mother, Thank you for all the supports and encouragement during This thesis is being made.. ACKNOWLEDGEMENTS In the name of ALLAH SWT, the most Gracious, who has given me the strength and ability to complete this study. All perfect praises belong to ALLAH SWT, lord of the universe. May His blessing upon the prophet Muhammad SAW and member of his family and companions. I feel grateful to Allah S.W.T because this project has successfully completed. In completion this final year project, I was in contact with many people that contributed toward my understanding and problem solving. In particular, I wish to express my sincere appreciation to my project supervisor, Mr. Ismail Bin Ali for his guidance, advice and encouragement. I am deeply thankful to everyone who assisted me on this project especially to all staff FKM laboratory for their assistance and support. Besides that, I also would like to dedicate my deepest appropriation to all my fellow friends especially to automotive student batch 04/08 for their support and encouragements during this project are performed. Not forgetting my family members in giving me lots of supports in the aspects of moral, social and financial during my degree. This project definitely not exists without full encouragement from them. ABSTRACT Modification on intake port flow by enlarging the intake port area can increase engine performance. Higher air flow rate entered the intake port resulting higher air-fuel rate burn thus increased the performance of the engine. This report are consist of experiment of intake port flow between two cylinder head, Toyota 4AGE 1.6L and Proton 4G92 1.6L.Modification works will be porting, polishing, removing valve guide and additional mounted velocity stack. Effects of modification through both cylinder head are experimentally tested by opening valve lift with significant value by calculations using Superflow® SF-1020 Flowbench machine. The experiment will consist of intake valve flow rate, the effect of velocity stack and swirl motion in bore. It is proved by experiment result that porting, polishing and removal valve guide in the intake port area works significantly increased the flow into the engine and consequently changes the swirl speed to a higher values for both cylinder head and tremendous increased when the velocity stack is added along with the modification works. ABSTRAK Modifikasi pada bahagian kemasukan aliran jisim udara dengan pembesaran kawasan kemasukan aliran udara boleh meningkatkan prestasi enjin. Peningkatan kenaikan kadar kemasukan jisim udara meningkatkan kadar pembakaran jisim udara dan bahan bakar yang mengakibatkan peningkatan mendadak prestasi enjin. Repot experimen ini mengandungi kajian tentang kadar jisim udara masuk antara dua jenis kepala silinder iaitu Proton 4G92 1.6L dan Toyota 4AGE 1.6L.Kerja-kerja modifikasi adalah seperti ”porting”, ”polishing”, penghapusan panduan injap udara masuk dan penambahan cerobong kelajuan.Kesan daripada modifikasi kedua-dua kepala silinder akan diuji keberkesanannya melalui experimen dengan pembukaan injap udara masuk melalui pengiraan kadar pembukaan injap udara masuk dengan menggunakan mesin Superflow® SF-1020 Flowbench.Experimen pada ruang aliran jisim udara masuk ini merangkumi kadar jisim udara masuk, kesan penggunaan cerobong kelajuan dan kesan pergerakan pusaran pada bor.Telah terbukti dalam experimen bahawa kesan daripada kerja-kerja ”porting”, ”polishing” dan penghapusan panduan injap udara masuk di kawasan kemasukan aliran udara dapat meningkatkan kadar jisim udara yang masuk ke dalam kepala silinder mengakibatkan perubahan kadar kelajuan pusaran di dalam bor kepada kedua-dua kepala silinder and peningkatan yang menakjubkan jika modifikasi disertakan juga dengan cerobong kelajuan udara. TABLE OF CONTENTS CHAPTER TITLE PAGE THESIS TITLE i DECLARATION ii DEDICATION iii ACKNOWLEDGEMENT v ABSTRACT vi TABLE OF CONTENT viii LIST OF TABLES xi LIST OF FIGURES xii LIST OF SYMBOLS xiv LIST OF APPENDICES xv CHAPTER I INTRODUCTION 1 1.0 Project Background 1 1.1 Problem Statement 2 1.2 Objectives of the Project 2 1.3 Scopes of the Project 3 CHAPTER II LITERATURE STUDY 5 2.1 Introduction 5 2.2 Engine Specification 6 2.2.1 Intake Port Design 6 2.2.2 Poppet Valve Design 7 2.3 Intake Port Flow 7 2.4 Flow Losses in an Intake Port 11 2.5 Technique of Modifications 12 2.6 Swirl 13 2.6.1 Swirl Meter 14 2.7 Coefficient of Discharge 15 2.8 Flowbench system 17 CHAPTER III METHODOLOGY 19 3.1 Porting 19 3.1.1 Porting Tools 20 3.2 Polishing 23 3.2.1 Polishing Tools 23 3.2.2 Polishing Work 24 3.3 Velocity Stack 25 3.4 L/D Ratio 27 3.4.1 L/D Ratio for Both Cylinder Head 28 3.5 Flowbench Analysis 28 3.5.1 Analysis Parameter 30 3.5.2 Valve Lift Actuations 31 3.5.3 Steps for Measurement 32 3.6 Analysis for Both Engines 34 3.7 Airflow Measurement 35 3.8 Formula Used 35 CHAPTER IV RESULT AND DISCUSSIONS 4.1 Proton Intake Port Result 38 4.1.1 Before Cleaning Process 38 4.1.2 After Cleaning Process 39 4.1.3 Modification without Velocity Stack 40 4.1.4 Modification with Velocity Stack 41 4.1.5 Swirl Result 42 4.1.6 Valve Flow Percentage Increment 43 4.17 Expected Horsepower 44 4.2 Toyota Intake Port Result 45 4.2.1 Before Cleaning Process 45 4.2.2 After Cleaning Process 46 4.2.3 Modification without Velocity Stack 47 4.2.4 Modification with Velocity Stack 48 4.2.5 Swirl Result 49 4.2.6 Valve Flow Percentage Increment 50 4.2.7 Expected Horsepower 52 4.3 Analysis Comparison between Proton and 53 Toyota Intake Port Result CHAPTER V CONCLUSION AND RECOMMENDATIONS 57 5.1 Conclusions 57 5.2 Recommendations 59 REFERNCES 61 APPENDIX A-H 62-94 LIST OF TABLES TABLE NO. TITLE PAGE 1 Proton engine 4G92 1.6L 6 2 Toyota engine 4AGE 1.6L 6 3 Percentage of flow losses in intake port 12 4 Various stones type and functions 22 5 L/D ratio used for comparison both cylinder 28 head testing 6 Flow range used for analysis both cylinder head 30 7 Coefficient of Discharge for Proton standard and 55 modified intake port with velocity stack at each intake valve lift opened. LIST OF FIGURES FIGURE NO TITLE PAGE 1 Flow chart of the project 4 2 Proton intake port design 7 3 Toyota intake port design 7 4 First Stage of valve lift operation 8 5 Second stage of valve lift operation 9 6 Final stage of valve lift operation 10 7 Flow losses in the intake port 11 8 Swirl direction view from top 13 9 Swirl meter used for swirl experiment 14 10 Flow region in low intake valve lift open 16 11 Flow region in intermediate valve lift open 16 12 Flow region in high intake valve open 17 13 Schematic of Flowbench layout 17 14 Proton intake port after porting works 20 15 Toyota intake port after porting works 20 16 Air grinder for porting modification 21 17 W179 cylindrical type abrasives 23 18 Flapwheel used for polishing works 23 19 Roll of cloth that used for polishing 24 20 A25 ball type abrasives tool 24 21 Proton intake port after polishing modification 24 22 Toyota intake port after polishing modification 25 23 Velocity stack that mounted to Proton intake port 26 24 Velocity stack that mounted to Toyota intake port 26 25 Superflow® SF-1020 Flowbench machine 29 26 Valve lift adapter for Toyota experiment 31 27 Test analysis is performed 33 28 Dial gauge position 33 29 Valve flow versus valve lift for Proton standard 38 intake port before cleaning. 30 Valve flow versus valve lift for Proton standard intake 39 port after cleaning 31 Valve flow versus valve lift for Proton standard and 40 modification intake port without velocity stack 32 Valve flow versus valve lift for Proton standard and 41 modified intake port with velocity stack 33 RPM versus L/D ratio for Proton standard and modified 42 intake port without velocity stack 34 Flow percentage versus valve lift for Proton porting 43 and polishing with standard intake port results 35 Horsepower versus valve lift for Proton porting and 44 polishing with standard intake port results. 36 Valve flow versus valve lift for Toyota standard intake 45 port before cleaning 37 Valve flow versus valve lift for Toyota standard intake 46 port after cleaning 38 Valve flow versus valve lift for Toyota standard and 47 modified intake port without velocity stack 39 Valve flow versus valve lift for Toyota standard and 48 modified intake port with velocity stack 40 RPM versus valve lift for Toyota standard and 49 modified intake port without velocity stack 41 Valve flow increment versus valve lift for Toyota 50 porting and polish intake port with standard intake port results.
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