Finite Element Simulation for Improved Design of Plastic Intake Manifold for Four Cylinder Engines

In order to reduce the weight for improving fuel efficiency and enhance the performance of automobile engines, research into plastic manifolds compared to conventional aluminium and iron manifolds is becoming a trend for the intake structure design. In this paper, finite element simulation is employed to design and optimize a plastic manifold for a four cylinder intake structure. The yield strength of intake manifold structure for an applied burst pressure of 6.5bar is verified using finite element analysis. Based on the simulation results and identification of strength critical zones, stiffeners were introduced to improve the plastic intake manifold design for an operational temperature range of 20-120 degrees Celsius.