The Effect of Unconventional Airbox Design on High-Performance Engine Efficiency

School Name

Spring Valley High School

Grade Level

10th Grade

Presentation Topic

Engineering

Presentation Type

Non-Mentored

Abstract

Automotive engine efficiency has advanced due to the design optimization of interior components. Most engine components transport air or fluids, so aerodynamic optimization is critical to improving flow efficiency. Computational Fluid Dynamics (CFD) and Computer Assisted Design (CAD) are utilized to aerodynamically optimize these components. Incidentally, a significant component that transports air is the air intake. The purpose of this study was to evaluate the effects of modified airbox (air intake) shapes on their internal airflow dynamics. It was hypothesized that redesigning internal surfaces and curvature of airbox walls would affect internal pressure and velocity when CFD simulations were being conducted. These metrics could significantly affect the real-world efficiency of engines, and thus their emissions. So, it is justifiable to conduct experiments on airboxes in order to balance outlet airflow. One airbox model was created using CAD, and three variants were derived. All models were simulated in CFD to find static air pressure, and outlet mass flow rates. Standard deviations of outlet mass flow rates were taken and compared across the models. Variant-2 had the lowest standard deviation in mass flow rates (SD = 0.0063248) and demonstrated a 15.678% increase in pressure drop compared to the base model. For these reasons, Variant-2 was deemed the most successful model. Overall, previous studies made connections between mass flow rates, air pressure, and engine fuel efficiency and power output. Therefore, it could be concluded that Variant-2 would theoretically be the most beneficial to an engine’s fuel efficiency and power output.

Location

Furman Hall 201

Start Date

3-28-2026 11:00 AM

Presentation Format

Oral and Written

Group Project

No

COinS
 
Mar 28th, 11:00 AM

The Effect of Unconventional Airbox Design on High-Performance Engine Efficiency

Furman Hall 201

Automotive engine efficiency has advanced due to the design optimization of interior components. Most engine components transport air or fluids, so aerodynamic optimization is critical to improving flow efficiency. Computational Fluid Dynamics (CFD) and Computer Assisted Design (CAD) are utilized to aerodynamically optimize these components. Incidentally, a significant component that transports air is the air intake. The purpose of this study was to evaluate the effects of modified airbox (air intake) shapes on their internal airflow dynamics. It was hypothesized that redesigning internal surfaces and curvature of airbox walls would affect internal pressure and velocity when CFD simulations were being conducted. These metrics could significantly affect the real-world efficiency of engines, and thus their emissions. So, it is justifiable to conduct experiments on airboxes in order to balance outlet airflow. One airbox model was created using CAD, and three variants were derived. All models were simulated in CFD to find static air pressure, and outlet mass flow rates. Standard deviations of outlet mass flow rates were taken and compared across the models. Variant-2 had the lowest standard deviation in mass flow rates (SD = 0.0063248) and demonstrated a 15.678% increase in pressure drop compared to the base model. For these reasons, Variant-2 was deemed the most successful model. Overall, previous studies made connections between mass flow rates, air pressure, and engine fuel efficiency and power output. Therefore, it could be concluded that Variant-2 would theoretically be the most beneficial to an engine’s fuel efficiency and power output.