Implementation of Turbocharger on a FSAE car

Powertrain Subsystem
Team KART, Formula SAE Team of IIT Kharagpur

Engine: KTM Duke 390 Single cylinder, 4 valve DOHC, Naturally aspirated
Bore: 89 mm
Stroke: 60 mm
Displacement: 373.3 cc
Compression ratio: 12.5
Stock maximum power output: 43 HP@9250 RPM
Stock maximum torque output: 35 Nm@7500 RPM
Simulated maximum power output with 20 mm restrictor: 33 HP@7500 RPM (naturally aspirated)
Simulated maximum torque output with 20 mm restrictor: 33 Nm @5750 RPM (naturally aspirated)
Assumptions of the turbocharged model:
1. Since the compression ratio of the engine is not being changed, a low boost configuration will be targeted for. The target power output of the
turbocharged engine will be same as that of the stock engine model without the 20 mm restrictor.
2. Air fuel ratio of the turbocharged system will be set at 12:1 for enhanced cooling with necessary enrichments.
3. The displacement of the engine being less than 500 cc, GT0632 turbocharger is chosen as appropriate.
4. The compressor operating points are approximated using ideal gas laws and corrected through simulation by balancing torque on the turboshaft.
5. Target boost pressure: 7.5 psi
6. Regulation of boost pressure in the model is done with the help of a PID controller actuating the waste gate. In practice the same will be done by
adjusting the waste gate nut, to set a particular boost pressure, beyond which if the manifold pressure exceeds, waste gate would open up.
Simulation software: Ricardo WAVE
Fuel used in simulation: INDOLENE
Combustion model: SIWIEBE
Heat transfer model: WOSCHNI

Simulated naturally aspirated FSAE engine brake power curve

Simulated naturally aspirated FSAE engine brake torque curve

(Ignore the initial spike at low engine speeds)

Naturally aspirated stock engine power curve (wheel dyno)

Data from: RaceDynamics India

Naturally aspirated engine torque curve (wheel dyno)

Data from: RaceDynamics India

Superimposed curves (compressor map & calculated operating points) for turbo speed calculation

Compressor operating points

Turbine operating points

Simulated turbocharged FSAE engine brake power curve

Simulated turbocharged FSAE engine brake torque curve

Ricardo WAVE model of the turbocharged engine