DESIGN OF A SUPERCHARGER FOR IMPROVED

ENGINE PERFORMANCE

Abstract:The following abstract summarizes the development of a supercharger to

improve engine performance. In internal combustion engines, the supercharger is designed
to increase intake air pressure and density, resulting in improved combustion efficiency
and higher power output. A compact, efficient compressor with variable speed control, a
robust drive system,impeller and an integrated intercooler for temperature regulation are
key design elements. The design has been validated through computational simulations and
experimental testing, demonstrating significant gains in horsepower and torque while
maintaining fuel efficiency. This innovative supercharger has the potential to revolutionize
engine efficiency and power output in a wide range of applications, from high-performance
sports cars to industrial machinery.

INTRODUCTION
The development of a supercharger is an important endeavor in the fields of automotive and
mechanical engineering, with the goal of improving the performance and efficiency of internal
combustion engines. This novel device works on the fundamental principle of forced induction,
which involves compressing incoming air to provide more oxygen to engines, resulting in
increased power output. To achieve optimal compression ratios, a well-executed supercharger
design requires a delicate balance of factors such as rotor and housing geometry, material
selection, and precision engineering. It is critical in increasing engine power, improving throttle
response, and overall vehicle performance. To ensure seamless integration, engineers must
consider factors such as reliability, heat management, and compatibility with the engine
system.As the automotive industry prioritizes fuel efficiency and performance, the design of
superchargers remains a dynamic and critical aspect of field innovation.

Fig 1-Twin screw supercharger construction Fig 2- Supercharger Working

PROBLEM STATEMENT
Design a supercharger for 450hp power and 6650 rpm for a vehicle Ford Raptor R and desired
output:- 700 hp. Many vehicles face limitations in engine performance, affecting speed and
efficiency. Traditional engines lack power, especially at lower speeds or during acceleration.
This hampers overall vehicle performance and user experience.

OBJECTIVES
➢ Boost Power: Create a supercharger system that increases engine power, improving
vehicle acceleration and speed capabilities for better performance.
➢ Enhance Efficiency: Design the supercharger to optimize fuel usage, making the vehicle
more fuel-efficient without compromising on power.
➢ Ensure Simplicity: Develop a user-friendly supercharger design that's easy to understand,
assemble, and operate, suitable for study purposes.
➢ Cost-Effectiveness: Build the supercharger system using affordable materials and
methods, ensuring it remains budget-friendly for educational purposes.
➢ Learning Experience: Provide a practical learning opportunity for students to understand
the principles of supercharger design, mechanics, and their impact on engine
performance.

DESIGN PARAMETERS AND CALCULATIONS

The supercharger contains various crucial components like
1) Rotar
2) Casing
3) Pulley
4) Drive Mechanism
5) Bypass valve

Vehicle Name: FORD RAPTOR R

Engine Specification:
5.2L Supercharger V8 Engine
Power: 450 hp
Torque: 691 N-m

Airflow rate without any boost: 750 cfm

pressure ratio= desired hp / existing hp
pressure ratio= 1.55hp
pressure ratio is is total absolute pressure produced by supercharger over atmospheric pressure

Desired horsepower = (Engine displacement * Engine speed * Volumetric Efficiency * Boost

pressure) / Efficiency
Desired horsepower = 700hp
Boost pressure = (manifold pressure - atmospheric pressure) / atmospheric pressure
boost pressure =12 psi

desired air flow rate = basic airflow rate* pressure ratio

desired air flow rate = 1162.5 cfm

supercharger speed= desired flow rate / displacement per revolution

supercharger speed= 2142.857 rpm

displacement per revolution= engine displacement * boost pressure/12.19*temperature=0.01 m3

engine displacement= 4 liters
displacement per revolution= 0.01m3/rev = 0.35ft3

Effective compression ratio of supercharger= (Boost Pressure + Atmospheric Pressure) /

Atmospheric Pressure

Compression ratio without supercharger is 10:1

Compression ratios in naturally aspirated gasoline engines typically range from 8:1 to 12:1, with
high-performance and race engines sometimes exceeding 12:1

Effective compression ratio of supercharger= 1.68

supercharger outlet pressure = P1 * (1 + PR)

P1 is Pressure at inlet of supercharger
PR is Atmospheric Pressure
supercharger outlet pressure = 37.485 psi

Drive Mechanism:
drive power =boost* desired airflow/229
drive power =60.917 hp
dividing drive power by 97 percent for belt efficiency and 60 percent adiabatic efficiency.
knowing this number we are looking for a belt which is able to carry 103 hp power.

pulley ratio= supercharger rpm at desired flow rate/ gear ratio* engine redline rpm
pulley ratio= 1.5

crankshaft pulley diameter=pulley ratio* supercharger pulley diameter

let assume that pulley diameter is 90 mm
crankshaft pulley diameter= 135 mm
Belt length = 2 * Center distance + π * (Crank pulley diameter + Supercharger pulley diameter) /
2
Belt length = 753.25 mm

Belt velocity= crankshaft pulley diameter * speed/ 229

Belt velocity= 156.201 ft/rev
229 is conversion factor we are converting mm into inches
130 mm =5.11 inch
we are converting power into lb-ft/dec
1 hp = 550 lb-ft/sec

=60*550 lb-ft/sec

force = power/velocity
force = 60 pounds= 220N
new fuel pressure= stock fuel pressure*(old airflow rate/new airflow rate *pressure ratio)2 +
boost
new fuel pressure= 104 psi

Rotor Design Calculation:

t = C_1 * D * sqrt(P_in / (rho * V_in^2))
t is the impeller blade thickness (m)
C_1 is a constant that depends on the blade shape (typically between 0.06 and 0.12
D is the impeller diameter (m)
P_in is the inlet air pressure (Pa)
V_in is the inlet air velocity (m/s)
Impeller blade thickness= 0.288

first we have to find V in so,

V_in = Q / (𝝅D_i^2 / 4)
where q = volumetric flow rate (m^3/s)

q =(P_boost - P_in) / (rho * V_tip)

p_boost= 82737.12 Pa
p_ in=101352.932 Pa
Volumetric Flow Rate = 0.5 m^3/s
V_in = 70.3513 m/s

V_tip = 𝝅D_i * N / 60
 impeller diameter = sqrt(4 * Q / (𝝅 * V_tip * n))
(impeller blade angle) beta = tan^-1((V_tip * U) / (C_m * W_1))
Impeller diameter = 0.12 mm

where, U is tangential velocity

C_m= C_m is the impeller mean coefficient
V_r is the relative velocity of the air at the impeller inlet (m/s)
tangential velocity=π * d * w / 60
where d is impeller inlet diameter
tangential velocity= 0.288 m
V_r = sqrt(u1^2 + (u2 - w)^2)

MATERIAL SELECTION
1) Rotar: A supercharger's rotor is typically made of high-strength materials to withstand the
high-speed rotation as well as the forces involved in compressing and delivering air to the
engine. The materials used are
I. Aluminum: It is a lightweight and durable material commonly used for
supercharger rotors. A356 and A380 are commonly used aluminum alloys
II. Titanium: Ti-6Al-4V is commonly used Titanium alloy
III. Magnesium: AZ91D and AZ61D are mostly used Magnesium alloys.

2) Casing: The casing or housing of a supercharger, also known as the supercharger housing or
supercharger case, is an essential component that encloses the internal components of the
supercharger and provides structural support, airflow management, and connections to the engine
and intake system. The casing is typically made from durable materials that can withstand the
high-pressure and high-temperature conditions within the supercharger .Some examples of
specific materials used in the casings of popular superchargers:

I. Eaton TVS supercharger: Cast aluminum

II. Rotrex C38-91 supercharger: Cast iron
III. Whipple W150AX supercharger: Magnesium alloy
IV. Magnuson Heartbeat 2300 supercharger: Stainless steel

3) Pulleys:The material used for supercharger pulleys is typically a high-strength, lightweight

alloy such as
I. Aluminum is widely used as it is durable , Availability, weight to strength ratio and cost.
II. Carbon Fiber is the best material for this application but cost is a major factor.
III. Steel is a more durable and wear-resistant material than aluminum, but it is also heavier.

Results and Discussion:

Fig 3 CAD Model of system Fig 4 Pulley

Fig 5: CasingCasing Fig 6: Screw Rotor

 Fig 8: Structural Analysis of Pulley

Fig 9: Total Deformation Analysis of Pulley

 Fig 10: Shear stress Analysis of Pulley

FUTURE SCOPE

● Improved Efficiency: Advancements in materials and design will lead to more efficient
superchargers.
● Hybrid and Electric Vehicles: Superchargers can enhance the performance of hybrid
setups and potentially boost power in electric vehicles.
● Emissions Reduction: Superchargers can enable downsizing, reducing emissions without
sacrificing performance.
● Tuning and Customization: Superchargers offer tunability for enthusiasts and will
continue to grow in the aftermarket segment.
● OEM Integration: Automakers may integrate superchargers to meet emission standards
and improve performance.

CHALLENGES

➢ Emissions and Fuel Efficiency: Balancing performance and fuel efficiency is a challenge
as emission standards become stricter.
➢ Electrification: Superchargers may become less relevant with the shift to electric
vehicles.
➢ Heat Management: Effective cooling solutions are needed to manage heat generated by
superchargers.
 ➢ Cost: Reducing the cost of designing, manufacturing, and installing supercharger systems
is an ongoing challenge.
➢ Reliability: Ensuring long-term reliability is crucial due to the wear and tear from high
rotational speeds.

CONCLUSION

Supercharger design remains a dynamic and critical aspect of automotive innovation, aiming to
strike the delicate balance between performance and efficiency. The pursuit of increased power
and improved environmental sustainability aligns with the industry's focus on technological
advancements. As engineering and material science continue to advance, superchargers will play
a pivotal role in shaping the future of automotive performance and efficiency.