- Email: [email protected]
Design&manufacturing of spiral intake manifold to improve Volument efficiency of injection diesel engine byAM process
Available online at www.sciencedirect.com
ScienceDirect Materials Today: Proceedings 4 (2017) 1084–1090
www.materialstoday.com/proceedings
5th International Conference of Materials Processing and Characterization (ICMPC 2016)
Design&manufacturing of spiral intake manifold to improve Volument efficiency of injection diesel engine byAM process A. Manmadhacharya *, M. Santosh Kumara, Y. Ravi Kumara a
Department of Mechanical Engineering, National Institute of Technology Warangal, Telangana, India, 506004.
Abstract Intake manifold is an arrangement of tubing with several intake or outlet passages, through which a gas or liquid is gathered or distributed. The design of intake manifold has significant effect on engine performance characteristics. Volumetric efficiency is a quantitative comparison (typically expressed as a percentage) of physical cylinder volume to the volume of air entering in the cylinder at any given rpm. Current study was conducted to develop a spiral intake manifold model to predict gas flow in the intake system of a single cylinder internal combustion engine. Design of spiral intake manifold was altered with variable intake areas and the intake runners are bent around a common axis. The designed spiral intake manifold was fabricated using Additive Manufacturing (AM) technique. In this work, a Kriloskar single cylinder diesel engine has been used, which is coupled with tachometer and dynamometer. Generally, the intake manifold in use is a straight pipe through which air is sucked inside the engine. For the purpose of this study, the intake manifold was dismounted from the engine and the AM manufactured spiral intake manifold has been fitted. The spiral intake manifold was installed on the test rig and volumetric efficiency was calculated accordingly. Comparison is made with respect to volumetric efficiency using with and without using spiral intake manifolds. To conclude by using the spiral intake manifold, volumetric efficiency of the engine was enhanced at different injection pressures and varying loads. ©2017 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and Characterization (ICMPC 2016). Keywords:Intake manifold, Volumetric efficiency, Design of manifold, Additive Manufacturing, Injection diesel engine.
* Corresponding author. Tel.:+91 9885660279. E-mail address:[email protected] 2214-7853©2017 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and Characterization (ICMPC 2016).
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
1085
1. Introduction Diesel engine is one of the Internal Combustion (IC) engine, the air-fuel mixture ignition is done by compression of fuel at high temperature, and it operates by diesel cycle [1]. Air intake manifold system is an essential part in diesel engine. It supplies the fuel/air mixture to the cylinders. An intake manifold is an integrated assembly that sits atop the engine, consisting of a series of tubes which distribute fresh outside air to each and every cylinder. Fig. 1 shows intake manifolds for inline engines are often mounted on the side of the engine [2].
Fig. 1: Air intake manifold of the car [2]
Intake manifolds contains of a chamber, to the inlet of which run off the accelerator, with the certain feeds to pipes it leads to each cylinder. Standard intake manifolds for automobiles have fixed air flow. Stable intake manifold, the speed at which intake tuning is fixed. At one particular rpm stable intake manifold can be perfect, so it is advantages to create a process to vary the intake length/volume, since the engine runs at ample speeds. Air intake manifold as to deliver more air as possible for a given size (volumetric efficiency) [3]. The design of the intake manifold has an important effect on the engine efficiency parameters. Design aspects are: low resistance to air flow; allocation of air and fuel in the cylinders; advantage of ram and tuning effects; enough heat to check enough fuel vaporization with carbureted engines. The air intake manifold increases the engine efficiency by feeding the amount of air to the combustion chamber of an IC engine [4]. Generally, testing of intake manifold is done by direct prototypes & running the engine. The design and manufacturing of intake manifold by Additive manufacturing (AM) takes less time and cost compared to other techniques [5]. To increase airflow there are three ways. The first, control the force of the air velocity to fill the combustion chambers. By this cams keep the valves open before top dead center (TDC) and after bottom dead center (BDC). If all the causing parts are balance to the same rpm range air carriers to fill the combustion chamber as the piston moves upward. It causes to the speed of the intake charge gives the inertia to oppose backward flow, to a point. The second, this is related to inertia tuning, its complicated to run at a particular rpm. Ports works well by induction wave tuning.The third, shapes of port and valve improves the flow. Swirl is one of the principal means to ensure rapid mixing between fuel and air in diesel engine and is used in gasoline engines to promote rapid combustion [6]. The swirl level at the end of the compression process dependent upon the swirl generated during intake process and how much it is amplified during the compression process. In diesel engine, as fuel is injected, the swirl converts it away from the fuel injector making fresh air available for the fuel about to be injected [7].In this work, try to improve the airflow in intake manifold by changing cross-sectionshape to get swirl motion of intake air. Severalresearchers are working to get swirl effect in intake manfold. Phaneendra et al, for better turbulence the surface of the inlet manifolds (compression ignition engine) will be made rough and unpolished. And to get better turbulence the helical threads were arranged in the inlet manifolds [8]. Benny Paul1andV. Ganesan, threedimensional model of the manifolds (helical, spiral and helical-spiral) and the cylinder is created and meshed using
1086
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
the pre-processor GAMBIT. The flow characteristics of these engine manifolds are examined under transient conditions using Computational Fluid Dynamics (CFD) code STAR-CD [9]. Ramesh et al deals with experimental investigation of swirling flow in the cylinder of a spark ignited engine. Flow modification was carried out in two methods, by using a twisted tape in the manifold and shrouding the inlet valve [10]. The importance of paper is to design and manufacturing of spiral intake manifolds for the IC engine in order to create the turbulence by swirl with various cross section areas, further improve the volumetric efficiency. 2. Design of the spiral intake manifold The intake manifold was designed with 3-Dimenstional (3D) solid modeling software (Creo 3.0). It works based on feature-based, parametric modeling methods. While design a manifold, considered a spiral shape to get swirl motion of air in to intake manifold. Both the ends of the manifold have a circular cross section, with the various diameters. It’s one end is considered same as exist uniform intake manifold diameter of internal combustion engine and other end of manifold diameter considered as ratio of 1:3, i.e. one end of the manifold has a diameter of 45 mm whereas the other end of the manifold which sucks the air from outside has a diameter of 135 mm. The designed model was shown in the Fig. 2.
Fig. 2. Design of manifold with 1:3 variable cross sections
This 3D Computer Aided Design (CAD) model has all the geometric information about the manifold. This 3D CAD model converted to STL (Stereolithography) file format. In this stage 3D CAD model converts in to triangulation faceted model. STL is the format that AM machines understand. STL file is transferred to AM machine and some general manipulation to the file can be made such as orientation, scaling, slicing, supports and tool path generation. The file conversation and manipulation were done with Creo3.0 and Catalyst software respectively. 3. Manufacturing of the spiral intake manifold The AM method allows us to manufacture a non-uniform cross section throughout the model. AM process belonging to the generative (or additive) production processes unlike subtractive processes. AM describes a number of different technologies that material extrusion, vat photo polymerization, powder bed fusion, directed energy deposition, material jetting, binder jetting and sheet lamination systems. In this work, Dimension SST (Soluble Support Technology) 768 Fused Deposition Modeling (FDM) machine is used for building the designed spiral intake manifold. In FDM processes, the part is fabricated by deposition of layers contoured in a (x-y) plane two
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
1087
dimensionally. The third dimension (z) results from single layers being stacked up on top of each other physical layer model. The material used for manufacturing the manifold was ABS P400 (Acrylonitrile Butadiene Styrene). This engineering thermoplastic has good mechanical strength (22Mpa). Fig. 3 shows the manufacturing of intake manifold on FDM process.
Fig. 3. Manufacturing of manifold on FDM machine
In this process addition of support structures are required for overhanging features. The intake manifold model comes out of the machine along with the support structure. Support structures are deposited with lesser density as compared to part density by providing air gaps between two consecutive roads. The support and model materials are shown in brown and white colours which are shown in Fig. 3. In Dimension SST 768 FDM machine, water-soluble support structure material is used. After completion of AM model from FDM machine it is dipped in to support removal solution for 6 to 8 hours. The support material is relatively poor quality and dissolved easily once the complete part is dipped in to solution. Removed support structures and manufactured AM inlet manifold are shown in Fig. 4.
Fig. 4. Model and support materials in manifold
1088
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
4. Experimental setup In this work conducted experiments on a single cylinder Kirloskar make engine. The general specifications of the engine are given in Table 1. Table 1: Specifications of the Engine used Number of cylinders
1
Rated power
5 HP
Bore
80 mm
Stroke
110mm
Cooling medium
Water
Rated speed
1500 rpm
Brake output power
3.68 KW
Density of fuel
832 kg/m3
Calorific value of fuel
43626 kj/kg
Fuel Used
Diesel
Kriloskar single cylinder diesel engine was mounted on a test bench and connected with a hydraulic dynamometer brake in order to provide the load for the engine. This dynamometer, type water brake, has been manufactured for many years and noted for his high power capability and relatively low manufacturing cost as compared to other. Both power and torque are measured using this dynamometer. The quantity of consumed fuel is measured using a mass flow meter for purpose of Carioles effect type. Engine speed is measured by an optical tachometer. Schematic layout of the experimental setup was shown in Fig. 5.
Fig. 5. Experimental setup (1) Engine (2) Dynamometer, (3) Fuel measurement system (4) Gas analyzer (5) Dynamometer control unit, (6) Shaft, (7) Exhaust pipe.
The intake manifold in use is a straight pipe through which air is sucked inside the engine. For the purpose of the experiment, the straight pipe intake manifold was dis-mounted from the engine and the manufactured inlet manifold has been fitted, it is shown in Fig. 6. The engine was operated at different loads.
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
1089
Fig. 6. Manufactured intake manifold fitted to engine
5. Results The designed and manufactured manifold was installed on the test rig and volumetric efficiency was calculated accordingly and compared the same with the volumetric efficiency of the engine straight pipe intake manifold. The graphs are obtained at different injection pressure.The volumetric efficiency at 200 bar and 240 bar are shown in Fig.7(a)and Fig.7(b) respectively. The black line in the graph represents the volumetric efficiency of the engine with a straight pipe manifold and the red line represents the volumetric efficiency of the engine after the installation of the spiral manifold with a ratio of 1:3. It is clearly evident from the graphs that the volumetric efficiency of the engine is higher when the spiral intake manifold was used. A varying trend is observed when the traditional manifold was used, while a gradual increase is observed when the experimental manifold is used.The engine was operated at low speeds, in order to get low mechanical losses, fast combustion and for good combustion efficiency.
Fig. 7. Volumetric efficiency VS load on the engine at 200and 240 bar.
1090
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
6. Conclusion A good swirl promotes the fast combustion and improves the efficiency. After analyzing the graphs, this effect observed in our manufactured inlet manifold. The volumetric efficiency was increased slightly, when the experimental designed and manufactured manifold was used on the engine than traditional manifold. It can be concluded that the size and shape of the intake manifold has a direct impact on the volumetric efficiency of the engine. By setting up the engine on the dyno and running it under different injection pressure and load, volumetric efficiency was improved. This was accomplished by changing the injection pressure the amount of fuel that the engine received. In the entire process the manifold used was made out of FDM machine, but for real time mass production this can be made from metal machines. References [1] J. B Heywood, Internal Combustion Engine Fundamentals, McGraw-Hill, New York, USA, 1988. [2] http://repairpal.com/intake-manifold. [3] R. Ilardo, C. B. Williams, Design and manufacture of a Formula SAE intake system using fused deposition modeling and fiber‐reinforced composite materials, Rapid Prototyping Journal, 16 ((2010) 174–179. [4] L.C.R. Lilly, Diesel Engine Reference Book. London: Butterworths, 1984. [5] P. K. Gurrala, S. P. Regalla, DOE Based Parametric Study of Volumetric Change of FDM Parts, 3rd International Conference on Materials Processing and Characterisation (ICMPC 2014), Hyderabad, India, 2014. [6] N. Watson and M.S. Janota, Turbocharging the Internal Combustion Engine, The Macmillan Press Ltd, 1982. [7] J.Martins, S. Teixeira, SCoene,design of an inlet track of a small i. c. engine for swirlenhancement, 20th International Congress of Mechanical Engineering, Gramado, RS, Brazil, 2009. [8] V. C. Phaneendra, V. Pandurangadu and M. Chandramouli, Performance evaluation of a four strokecompression ignition engine with various helicalthreaded intake manifolds, International Journal of Applied Research in Mechanical Engineering, 2 (2012) 52-60. [9] B. Paul, V. Ganesan, Flow field development in a direct injection diesel engine with differentmanifolds, International Journal of Engineering, Science and Technology, 2 (2010), 80–91. [10] C. R. Kumar and G. Nagarajan, Investigation of flow during intake stroke of asingle cylinder internal combustion engine, ARPN Journal of Engineering and Applied Sciences, 7 (2012) 180–186.
ScienceDirect Materials Today: Proceedings 4 (2017) 1084–1090
www.materialstoday.com/proceedings
5th International Conference of Materials Processing and Characterization (ICMPC 2016)
Design&manufacturing of spiral intake manifold to improve Volument efficiency of injection diesel engine byAM process A. Manmadhacharya *, M. Santosh Kumara, Y. Ravi Kumara a
Department of Mechanical Engineering, National Institute of Technology Warangal, Telangana, India, 506004.
Abstract Intake manifold is an arrangement of tubing with several intake or outlet passages, through which a gas or liquid is gathered or distributed. The design of intake manifold has significant effect on engine performance characteristics. Volumetric efficiency is a quantitative comparison (typically expressed as a percentage) of physical cylinder volume to the volume of air entering in the cylinder at any given rpm. Current study was conducted to develop a spiral intake manifold model to predict gas flow in the intake system of a single cylinder internal combustion engine. Design of spiral intake manifold was altered with variable intake areas and the intake runners are bent around a common axis. The designed spiral intake manifold was fabricated using Additive Manufacturing (AM) technique. In this work, a Kriloskar single cylinder diesel engine has been used, which is coupled with tachometer and dynamometer. Generally, the intake manifold in use is a straight pipe through which air is sucked inside the engine. For the purpose of this study, the intake manifold was dismounted from the engine and the AM manufactured spiral intake manifold has been fitted. The spiral intake manifold was installed on the test rig and volumetric efficiency was calculated accordingly. Comparison is made with respect to volumetric efficiency using with and without using spiral intake manifolds. To conclude by using the spiral intake manifold, volumetric efficiency of the engine was enhanced at different injection pressures and varying loads. ©2017 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and Characterization (ICMPC 2016). Keywords:Intake manifold, Volumetric efficiency, Design of manifold, Additive Manufacturing, Injection diesel engine.
* Corresponding author. Tel.:+91 9885660279. E-mail address:[email protected] 2214-7853©2017 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and Characterization (ICMPC 2016).
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
1085
1. Introduction Diesel engine is one of the Internal Combustion (IC) engine, the air-fuel mixture ignition is done by compression of fuel at high temperature, and it operates by diesel cycle [1]. Air intake manifold system is an essential part in diesel engine. It supplies the fuel/air mixture to the cylinders. An intake manifold is an integrated assembly that sits atop the engine, consisting of a series of tubes which distribute fresh outside air to each and every cylinder. Fig. 1 shows intake manifolds for inline engines are often mounted on the side of the engine [2].
Fig. 1: Air intake manifold of the car [2]
Intake manifolds contains of a chamber, to the inlet of which run off the accelerator, with the certain feeds to pipes it leads to each cylinder. Standard intake manifolds for automobiles have fixed air flow. Stable intake manifold, the speed at which intake tuning is fixed. At one particular rpm stable intake manifold can be perfect, so it is advantages to create a process to vary the intake length/volume, since the engine runs at ample speeds. Air intake manifold as to deliver more air as possible for a given size (volumetric efficiency) [3]. The design of the intake manifold has an important effect on the engine efficiency parameters. Design aspects are: low resistance to air flow; allocation of air and fuel in the cylinders; advantage of ram and tuning effects; enough heat to check enough fuel vaporization with carbureted engines. The air intake manifold increases the engine efficiency by feeding the amount of air to the combustion chamber of an IC engine [4]. Generally, testing of intake manifold is done by direct prototypes & running the engine. The design and manufacturing of intake manifold by Additive manufacturing (AM) takes less time and cost compared to other techniques [5]. To increase airflow there are three ways. The first, control the force of the air velocity to fill the combustion chambers. By this cams keep the valves open before top dead center (TDC) and after bottom dead center (BDC). If all the causing parts are balance to the same rpm range air carriers to fill the combustion chamber as the piston moves upward. It causes to the speed of the intake charge gives the inertia to oppose backward flow, to a point. The second, this is related to inertia tuning, its complicated to run at a particular rpm. Ports works well by induction wave tuning.The third, shapes of port and valve improves the flow. Swirl is one of the principal means to ensure rapid mixing between fuel and air in diesel engine and is used in gasoline engines to promote rapid combustion [6]. The swirl level at the end of the compression process dependent upon the swirl generated during intake process and how much it is amplified during the compression process. In diesel engine, as fuel is injected, the swirl converts it away from the fuel injector making fresh air available for the fuel about to be injected [7].In this work, try to improve the airflow in intake manifold by changing cross-sectionshape to get swirl motion of intake air. Severalresearchers are working to get swirl effect in intake manfold. Phaneendra et al, for better turbulence the surface of the inlet manifolds (compression ignition engine) will be made rough and unpolished. And to get better turbulence the helical threads were arranged in the inlet manifolds [8]. Benny Paul1andV. Ganesan, threedimensional model of the manifolds (helical, spiral and helical-spiral) and the cylinder is created and meshed using
1086
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
the pre-processor GAMBIT. The flow characteristics of these engine manifolds are examined under transient conditions using Computational Fluid Dynamics (CFD) code STAR-CD [9]. Ramesh et al deals with experimental investigation of swirling flow in the cylinder of a spark ignited engine. Flow modification was carried out in two methods, by using a twisted tape in the manifold and shrouding the inlet valve [10]. The importance of paper is to design and manufacturing of spiral intake manifolds for the IC engine in order to create the turbulence by swirl with various cross section areas, further improve the volumetric efficiency. 2. Design of the spiral intake manifold The intake manifold was designed with 3-Dimenstional (3D) solid modeling software (Creo 3.0). It works based on feature-based, parametric modeling methods. While design a manifold, considered a spiral shape to get swirl motion of air in to intake manifold. Both the ends of the manifold have a circular cross section, with the various diameters. It’s one end is considered same as exist uniform intake manifold diameter of internal combustion engine and other end of manifold diameter considered as ratio of 1:3, i.e. one end of the manifold has a diameter of 45 mm whereas the other end of the manifold which sucks the air from outside has a diameter of 135 mm. The designed model was shown in the Fig. 2.
Fig. 2. Design of manifold with 1:3 variable cross sections
This 3D Computer Aided Design (CAD) model has all the geometric information about the manifold. This 3D CAD model converted to STL (Stereolithography) file format. In this stage 3D CAD model converts in to triangulation faceted model. STL is the format that AM machines understand. STL file is transferred to AM machine and some general manipulation to the file can be made such as orientation, scaling, slicing, supports and tool path generation. The file conversation and manipulation were done with Creo3.0 and Catalyst software respectively. 3. Manufacturing of the spiral intake manifold The AM method allows us to manufacture a non-uniform cross section throughout the model. AM process belonging to the generative (or additive) production processes unlike subtractive processes. AM describes a number of different technologies that material extrusion, vat photo polymerization, powder bed fusion, directed energy deposition, material jetting, binder jetting and sheet lamination systems. In this work, Dimension SST (Soluble Support Technology) 768 Fused Deposition Modeling (FDM) machine is used for building the designed spiral intake manifold. In FDM processes, the part is fabricated by deposition of layers contoured in a (x-y) plane two
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
1087
dimensionally. The third dimension (z) results from single layers being stacked up on top of each other physical layer model. The material used for manufacturing the manifold was ABS P400 (Acrylonitrile Butadiene Styrene). This engineering thermoplastic has good mechanical strength (22Mpa). Fig. 3 shows the manufacturing of intake manifold on FDM process.
Fig. 3. Manufacturing of manifold on FDM machine
In this process addition of support structures are required for overhanging features. The intake manifold model comes out of the machine along with the support structure. Support structures are deposited with lesser density as compared to part density by providing air gaps between two consecutive roads. The support and model materials are shown in brown and white colours which are shown in Fig. 3. In Dimension SST 768 FDM machine, water-soluble support structure material is used. After completion of AM model from FDM machine it is dipped in to support removal solution for 6 to 8 hours. The support material is relatively poor quality and dissolved easily once the complete part is dipped in to solution. Removed support structures and manufactured AM inlet manifold are shown in Fig. 4.
Fig. 4. Model and support materials in manifold
1088
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
4. Experimental setup In this work conducted experiments on a single cylinder Kirloskar make engine. The general specifications of the engine are given in Table 1. Table 1: Specifications of the Engine used Number of cylinders
1
Rated power
5 HP
Bore
80 mm
Stroke
110mm
Cooling medium
Water
Rated speed
1500 rpm
Brake output power
3.68 KW
Density of fuel
832 kg/m3
Calorific value of fuel
43626 kj/kg
Fuel Used
Diesel
Kriloskar single cylinder diesel engine was mounted on a test bench and connected with a hydraulic dynamometer brake in order to provide the load for the engine. This dynamometer, type water brake, has been manufactured for many years and noted for his high power capability and relatively low manufacturing cost as compared to other. Both power and torque are measured using this dynamometer. The quantity of consumed fuel is measured using a mass flow meter for purpose of Carioles effect type. Engine speed is measured by an optical tachometer. Schematic layout of the experimental setup was shown in Fig. 5.
Fig. 5. Experimental setup (1) Engine (2) Dynamometer, (3) Fuel measurement system (4) Gas analyzer (5) Dynamometer control unit, (6) Shaft, (7) Exhaust pipe.
The intake manifold in use is a straight pipe through which air is sucked inside the engine. For the purpose of the experiment, the straight pipe intake manifold was dis-mounted from the engine and the manufactured inlet manifold has been fitted, it is shown in Fig. 6. The engine was operated at different loads.
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
1089
Fig. 6. Manufactured intake manifold fitted to engine
5. Results The designed and manufactured manifold was installed on the test rig and volumetric efficiency was calculated accordingly and compared the same with the volumetric efficiency of the engine straight pipe intake manifold. The graphs are obtained at different injection pressure.The volumetric efficiency at 200 bar and 240 bar are shown in Fig.7(a)and Fig.7(b) respectively. The black line in the graph represents the volumetric efficiency of the engine with a straight pipe manifold and the red line represents the volumetric efficiency of the engine after the installation of the spiral manifold with a ratio of 1:3. It is clearly evident from the graphs that the volumetric efficiency of the engine is higher when the spiral intake manifold was used. A varying trend is observed when the traditional manifold was used, while a gradual increase is observed when the experimental manifold is used.The engine was operated at low speeds, in order to get low mechanical losses, fast combustion and for good combustion efficiency.
Fig. 7. Volumetric efficiency VS load on the engine at 200and 240 bar.
1090
Manmadhachary A/ Materials Today: Proceedings 4 (2017) 1084–1090
6. Conclusion A good swirl promotes the fast combustion and improves the efficiency. After analyzing the graphs, this effect observed in our manufactured inlet manifold. The volumetric efficiency was increased slightly, when the experimental designed and manufactured manifold was used on the engine than traditional manifold. It can be concluded that the size and shape of the intake manifold has a direct impact on the volumetric efficiency of the engine. By setting up the engine on the dyno and running it under different injection pressure and load, volumetric efficiency was improved. This was accomplished by changing the injection pressure the amount of fuel that the engine received. In the entire process the manifold used was made out of FDM machine, but for real time mass production this can be made from metal machines. References [1] J. B Heywood, Internal Combustion Engine Fundamentals, McGraw-Hill, New York, USA, 1988. [2] http://repairpal.com/intake-manifold. [3] R. Ilardo, C. B. Williams, Design and manufacture of a Formula SAE intake system using fused deposition modeling and fiber‐reinforced composite materials, Rapid Prototyping Journal, 16 ((2010) 174–179. [4] L.C.R. Lilly, Diesel Engine Reference Book. London: Butterworths, 1984. [5] P. K. Gurrala, S. P. Regalla, DOE Based Parametric Study of Volumetric Change of FDM Parts, 3rd International Conference on Materials Processing and Characterisation (ICMPC 2014), Hyderabad, India, 2014. [6] N. Watson and M.S. Janota, Turbocharging the Internal Combustion Engine, The Macmillan Press Ltd, 1982. [7] J.Martins, S. Teixeira, SCoene,design of an inlet track of a small i. c. engine for swirlenhancement, 20th International Congress of Mechanical Engineering, Gramado, RS, Brazil, 2009. [8] V. C. Phaneendra, V. Pandurangadu and M. Chandramouli, Performance evaluation of a four strokecompression ignition engine with various helicalthreaded intake manifolds, International Journal of Applied Research in Mechanical Engineering, 2 (2012) 52-60. [9] B. Paul, V. Ganesan, Flow field development in a direct injection diesel engine with differentmanifolds, International Journal of Engineering, Science and Technology, 2 (2010), 80–91. [10] C. R. Kumar and G. Nagarajan, Investigation of flow during intake stroke of asingle cylinder internal combustion engine, ARPN Journal of Engineering and Applied Sciences, 7 (2012) 180–186.