Aspectos a serem considerados no desenvolvimento de um coletor de admissão plástico soldado por vibração

Abstract

Intake manifold project is essential to achieve the best internal combustion engine performance, and, therefore, several parameters should be considered during it development. For instance, an uneven air distribution lead to uneven cylinder volumetric efficiency, power loss and increased fuel consumption. On the other hand, pressures variations within intake manifold due to air flow transient effects could substantially increase or decrease the engine performance. Nowadays, in Brazil, the majority of the intake manifolds are fabricated from nylon with glass fiber which provides weight reduction, wall friction reduction and complex internal geometries. However, new factors become important like structural integrity reduction and withstand to burst pressure. This work presents the mainly development stages of a plastic intake manifold vibration welded. First, the basic intake manifold dimensions are defined through one-dimensional simulation. From this, three-dimensional model is built considering the engine compartment space available and aspects which allows injection and welding process of manifold shells. Then, intake manifold internal geometry is optimized to minimize air flow losses, increasing the volumetric efficiency. Intake manifold structural integrity and welding quality should de evaluated to withstand customer requirements. Confirming the intake manifold drawing through tests with prototype parts, production tooling is started.