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INTRODUCTION
Automotive
design
is
all
about
compromise,
parts
are
designed
to
meet
several
criteria
and
as
a
result
one
attribute,
e.g.
efficiency,
driveability
or
cost
is
often
chosen
in
favour
of
another,
e.g.
vehicle
performance.
This
is
also
the
case
with
the
Ford
Focus
RS
Mk2
intake
system.
The
standard
plenum
is
a
small,
cheap,
restrictive
plastic
item.
This
has
not
been
left
unnoticed
as
a
number
of
performance
versions
have
appeared
on
the
market.
A
computational
study
was
undertaken
to
assess
the
performance
of
the
standard
plenum
and
that
of
a
popular
aftermarket
plenum.
Simulation
results
show
that
the
aftermarket
unit
still
left
much
to
be
desired,
as
the
design
still
had
a
number
of
flow
restrictions
akin
to
the
standard
plenum.
The
study
then
focused
on
modifying
the
geometry
to
eliminate
or
reduce
these
restrictions.
This
developed
a
new
plenum
of
rational
design
from
the
inside-out.
The
new
unit
will
surpass
the
performance
of
the
standard
part
and
outperform
other
inferior
units
on
the
market
with
its
superior
cylinder
distribution
and
flow
characteristics.
Figure
2.
Vortex
restricting
flow
above
cylinder
1
SIMULATION
RESULTS
An
analysis
of
the
flow
in
the
standard
plenum
and
a
popular
aftermarket
version
was
conducted
using
Computational
Fluid
Dynamics
(CFD).
Aside
from
initial
simulations
to
establish
the
primary
grid
independent
solution,
40
further
simulations
were
performed
to
ascertain
flow
characteristics
for
the
baseline
models
and
modified
geometries
at
two
different
engine
speeds
and
higher
than
standard
boost
pressures.
Initial
results
highlighted
a
number
of
areas
for
improvement
akin
to
both
the
standard
and
aftermarket
versions.
For
example,
the
shape
of
the
plenum
above
cylinder
1
was
inducing
a
vortex
and
restricting
flow
to
this
cylinder
(fig
1&2).
This
causes
poor
cylinder
distribution
and
will
have
a
detrimental
effect
on
both
power
and
efficiency.
SUMMARY
With
a
number
of
modifications
to
the
plenum
shape,
an
optimum
was
reached.
Results
showed
superior
cylinder
distribution
and
an
average
6%
flow
increase
per
cylinder
(when
compared
to
the
aftermarket
product),
while
reducing
turbulence
and
increasing
the
average
velocity
into
the
ports,
providing
improved
flow
quality
and
quantity
for
better
combustion
and
an
increase
in
performance.
FLOW
As
the
air
travels
through
the
intake
system
it
must
flow
through
the
various
passages
and
parts
involved.
Reducing
the
obstruction
posed
by
these
sections
will
reduce
the
effective
pressure
drop
and
increase
the
flow
capacity
of
the
system,
although
care
must
be
taken
to
ensure
a
high
velocity
is
maintained
in
the
flow
closer
to
the
engine.