Interactions between fluids and structures occur in a wide range of engineering problems. The solutions to these problems are based on the relationship with continuum mechanics, and mostly these problems are solved with the help of numerical methods. Due to complex geometries, fluid physics, and fluid-structure interactions, addressing such issues is a computational challenge. The geometrical design of an air intake manifold is essential for the excellent performance of the IC engine. As per the SAE rule, the air intake manifold of the gasoline-fueled car should have a circular restriction of 20 mm, limiting the power of the engine. This research work aims to design an intake system that compensates for the power loss to the maximum extent and reduces the engine noise of the intake for the single-cylinder Honda CBR 250R engine. A 3D model of the actual manifold is designed to modify the intake manifold. With that geometry, Computational Fluid Dynamics (CFD) simulations were performed to optimize each section, including De Laval Nozzle, plenum, and runner, in such a way that there will be minimal pressure drop during the airflow. The flow was modeled as steady, Newtonian, and Incompressible. Continuity and Momentum conservation equations and the k-epsilon turbulence model were solved to obtain mean flow characteristics. Then, Lotus Engine Simulation software was used to optimize the size of the plenum to get the maximum power at higher RPM and maximum torque at lower RPM to enhance the performance of the car on the racing track. The runner length is tuned with the help of the Acoustics and Induction system theory to provide the ram effect in the naturally aspirated engine to achieve maximum volumetric efficiency. The exact injector position and fuel injection angle were decided by Prototype testing for proper air-fuel mixing. Finite Element Analysis (FEA) has been performed to determine the thickness and type of material for the manifold manufacturing to bear the backfire condition (pressure generated up to 3 bar) due to mistimed spark event during the frequent racing. The Formula SAE is an abstraction of the Automotive industry with more than 600 Formula Student combustion teams worldwide. The students face difficulty designing as there is a dearth of literature that systematically walks them through the designing steps. This research work walks the students chronologically by developing an optimized intake manifold.

Mr. NAFEES AHMAD, Aligarh Muslim University, INDIA Mr. Mehul Varshney, Department of Mechanical Engineering, Aligarh Muslim University, INDIA Mr. Mohammad Haani Farooqi, Assistant Professor, Mechanical Engineering Department, Aligarh Muslim University, INDIA Mr. Nakul Varshney, Aligarh Muslim University, INDIA