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1-CALCULATIONS FOR TURBO MATCHING - HONDA CIVIC EK9 - Dec 16, 2017 06:12 pm

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1-ENGINE DATA AND ENGINE TYPE

The calculations for turbo matching are given below , this calculations data has been obtained from honda civic EK9 SIR II ENGINE TYPE .The purpose of this calculation is to see what will be the effect of installing a turbo unit in this cars engine . 96-00 B16A4 Civic SiR II JDM SPECS [ TURBO ESTIMATION ]: -------------------------------------------------------------------- Model B16A - B16A6 Displacement (cc) 1595 Power Output (hp) 150 - 170 Compression Ratio 10.2:1 - 10.4:1 Bore (mm) 81.0 Stroke (mm) 77.4 VTEC YES Max RPM 8900 RPM. Years Produced 1988-2000 ------------------------------------------------------------------------------------------------------------------- Model B16B Displacement (cc) 1595 Power Output (hp) 185 Compression Ratio 10.8:1 Bore (mm) 81.0 Stroke (mm) 77.4 VTEC YES Max RPM 8900 RPM. Years Produced 1997-2000

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2-MATCHING TURBO STEP BY STEP :

TURBO CHARGER CALCULATIONS: *Cylinder Volume (cc) = Bore(mm) x Bore(mm) x (Pi*.00025) x Stroke(mm) *Cylinder Volume (cc) = 81 X 81 x ( 3.146 x 0.00025 ] x 77.4 =399.4015 cc CID x 0.5 x Max RPM / 1,728 = CFM This formula simply takes the engine’s size in cubic inches times .5 because in a four-cycle engine it takes two complete engine revolutions for all cylinders to complete their cycles. This value is then converted from cubic inches per minute to CFM by dividing it by 1,728, the number of cubic inches in one cubic foot (12 x 12 x 12 = 1,728). CFM= [ Engine CUbic Iches (Capacity) x [ max RPM / 2 ] ] / 1728 = [ 97.333 x 8900 ] / 3456 =236.565 the cubic feet per minute (CFM) of air flowing through the engine at the maximum revolution CFM= [ Engine CUbic Iches (Capacity) x [ max RPM / 2 ] ] / 1728 = [ 97.333 x 8900 ] / 3456 =250.655 [ ft3/min ] Calculate airflow for the X axis[ measured in lb/min ]: Mass Air Flow Rate = (HP target) x (air/fuel ratio) x (BSFC/60) For selected Turbo estimated power output from its installation is 470hp ,AirFuel Ratio =14.7:1 and BSFC = 0.50-0.60 from link given below [Note: If you don't have access to BSFC data, you can plug in an estimated value between .50-.60. ] BSFC is lbs fuel / (hp x hr) Mass Air Flow Rate = (HP target) x (air/fuel ratio) x (BSFC/60) Mass Air Flow Rate = 470 x [14.7 / 1 ] x [ 0.55 / 60 ] = 63.225 Ibm/min CID=Displacement in cc [Engine Power in cc] / 16.387 = 1595 / 16.387 ] = 97.333 cubic inches. where theoretical CFM = ( [ RPM / 2 ] x CID) / 1728 = [ 8900 x 97.33 ] / [ 1728 x 2 ] =250.655 [ ft3/min ] Volumetric airflow rate = CFM x PR = 250.655 x 0.57 = 142.87335 [ ft3/sec ] and actual CFM = 90% a good average number if you don't have access to measuring this. Multiply by .0610237 to convert cubic centimeter displacement into cubic inches. Calculate volumetric efficiency = (actual CFM / theoretical CFM) x 100 VE = [ [ 0.9 x250.655 ] / 250.655 ] x 100 = [ 225.5895 / 250.655 ] x 100 = 90% TurboCharger Efficency = 60-70% Calculate manifold absolute pressure [ map Or boost pressure ]: map = [(massairflow) x (639.6) x (460 + intake temperature F)] / (VE) x (RPM/2) x (CID) map = [ 63.225 x 639.6 x [460 + 100 ] ] / [ 0.9 x [8900/2] x 97.333 ] ] map =22645677.6/389818.665 = 58.092 psi Upwards of 100 degrees F is a good estimate for intercooled intake temps if you don't have access to measuring this. Plan on adding about 1psi to take into account pressure drops related to the intake and/or intercooler. Calculate pressure ratio for the Y axis = (14.7 + map) / 14.7 PR = [ 14.7 + 58.092 ] / 14.7 = 4.9518 If you're at sea level, 14.7psi will work. As elevation varies, this figure will need to be adjusted. from link given below Pressure Ratio for Turbo charger is : http://www.ebay.com/itm/HONDA-CIVIC-B-B16-B18-B20-T3-T4-Turbo-Kit-Integra-470HP-1996-1997-1998-1999-2000-/251200278074?hash=item3a7cb40e3a:m:mESkVv0xJLfxaWQNEwziChQ&vxp=mtr#vi-ilComp For explanation of above calculation open the link below to match the turbo step by step. click on link : http://www.musclecardiy.com/performance/match-turbocharger-engine-step-step-guide/# COMPRESSOR MATCHING: Typical two-valves-per-cylinder, push-rod engine: 80% VE Four-valve engine: 85% VE Four-valve engine w/variable valve timing: 95% VE So for our example, we’ll assume it’s a Four-valve engine w/variable valve timing: 95% VE where theoretical CFM = ( [ RPM / 2 ] x CID) / 1728 = [ 8900 x 97.33 ] / [ 1728 x 2 ] =250.655 [ ft3/min ] =250 CFM x .95 = 238.1222 CFM from ebay the turbo selected has low boost pressure of 8 psi and high boost pressure of 25 psi for a 470hp[target] so Low Boost Pressure Ratio at 8 psi: = 8 + 14.7 / 14.7 = 1.54421 PR High Boost Pressure Ratio at 25 psi: = 25 + 14.7 / 14.7 = 2.70 PR Mean Boost Pressure Ratio at 16.5 psi:=16.5 + 14.7 / 14.7 =2.122 from link we get density ratio as : http://www.musclecardiy.com/performance/match-turbocharger-engine-step-step-guide/# for a boost pressure of 16.5psi and PR=2.122 , We use figure in the above link 'Density ratio with after cooling ' figure to be DR=Density Ratio = 1.73 [ extending compressor efficiency to be 74% ] CFM with our turbo = CFM x DR CFM = 238.1222 x 1.73 DR = 411.951 CFM turbocharged Next we simply convert the turbocharged CFM into lbs/minute mass flow by multiplying it times standard air density, which is .069 lbs mass/cubic foot of air. Mass flow =411.951 CFM x .069 = 28.424 lbm/min of air mass flow The entire formula look like this, Massflow rate = (0.5 x CID x Max RPM / 1,728) x VE x DR x .069 Check: Engine power(hp) = Massflow rate x Boost Pressure =28.424 Ibm/min x 16.5 psi Engine power(hp)= 469 hp [ approx 470 hp ] Mass Air Flow Rate = (HP target) x (air/fuel ratio) x (BSFC/60) A/f Ratio = [ Mass Air Flow Rate x 60 ] / [ HP Target x BSFC ] A/F ratio = [ 28.424 x 60 ] / [ 470 x 0.55 ] = 6.597 As

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3-TURBINE MATCHING

You must know your turbine pressure or you’re flying blind. This can be easily accomplished by creating a 1/8-inch pipe tapped hole and installing an air tight fitting as a pressure tap.A turbine flow map plots expansion ratio on the X-axis and mass flow on the Y-axis. Note how the curve flattens out just before the 2.5 expansion ratio. This indicates that above this level of pressure the turbine is in choke and will not allow any higher rate of mass flow. Once this happens, if the engine is still accelerating, turbine end pressure rises very quickly and the engine has to begin overcoming higher backpressure, which is known as pumping loss. Also note how the efficiency plot begins to drop off rapidly once the turbine is into choke. This is why it’s easy to over boost an engine yet not realize the horsepower increase you planned for if your turbine is too small for the mass flow or horsepower you’re trying to produce. A turbine flow map will use expansion ratio on the X-axis. The following equation is how turbine expansion ratios are calculated. EMP + Atmos / Outlet P + Atmos = Expansion Ratio Where: EMP = Exhaust Manifold Pressure Outlet P = Turbine Outlet Pressure Atmos = Atmospheric Pressure Next, the turbine corrected flow is calculated in mass-flow for the Y-axis. This becomes a problem to correctly calculate due to the lack of accurate values available. The formula requires turbine pressure, which you will not know, and the engine’s actual exhaust temperature, another value you will not know. The standard formula for turbine corrected flow is as follows:

4-Matching constraints

MF √ ([EGT + 460] / 519) / [ (BP + EMP) / BP ] = Turbine Corrected Mass-Flow Where: MF = The Engine’s Actual Mass-Flow EGT = Exhaust Gas Temperature BP = Barometric Pressure EMP = Exhaust Manifold Pressure The numeric constants correct to absolute values. If you’re lucky enough to be developing your engine on a dyno however, access to turbine maps is not impossible. Usually, manufacturers will share turbine corrected flow maps with individuals who are engaged in advanced application engineering and have a need for this specific information. But in the hands of automotive enthusiasts, manufacturers have found that turbine maps create more questions than they answer. Mass Flow Rate [ Turbine ] = MassAirFlow + MassFuelFlow = mass_air [ [ A_F + 1 ] / A_F ] m_T=m_a + m_f = m_a [ [ A_F + 1 ] / A_F ] A_F=Air Fuel Ratio calculated above = 6.597 m_T = 28.424 x [ [ 6.597 + 1 ] / 6.597 ] = 32.732 Ibm/sec After cooler Eficiency is between 0.6 to 0.8 and race engine pressure of 1500 psi or 103.4214 bar

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