Design Optimization and Flow Analysis of An Air Intake System for SAE Student Formula Car

In the research of Formula SAE (FSAE) and racing car engines highlights the important role of air intake system design and performance to finding the volumetric efficiency, torque, and overall power output. As per the rules explains a 20 mm restrictor, which is limits the flow of air into combustion chamber and making the optimization of the intake system. Numerous studies have shown that venturi-type restrictors, when designed with convergent and divergent angles of approximately 12° and 6°, minimize pressure drop while allowing maximum airflow. In addition, the geometry of the intake manifold—including plenum shape (cylindrical, spherical, or elliptical) and runner length—has a direct impact on flow distribution, throttle response, and combustion efficiency. And we add the Advanced computational tools such as ANSYS Fluent, SolidWorks Flow Simulation, along with experimental validation, we have been widely utilize to predict and refine airflow moment. Then the innovations have focused to reducing pumping losses through barrel-type throttle bodies, we use RAM theory for plenum design, and use the variable-length intake manifolds for better sustain across different RPM ranges. with these approaches proves that careful optimization of restrictor geometry, plenum volume, and runner tuning can also improve mass flow rate, minimize pressure losses, and also enhance the performance and efficiency of FSAE race cars.