Lightweight Design and Structural Analysis of Air Intake Manifold Using Composites

This research presents a finite element analysis (FEA)-based investigation into the structural performance of an air intake manifold made from four different materials: Aluminum, Polyamide 6 (PA6), Polypropylene (PP), and Carbon Fiber Reinforced Polymer (CFRP). In response to the automotive industry's increasing demand for lightweight, fuel-efficient, and highperformance vehicles, the study explores alternative materials that can reduce component weight without compromising structural integrity. The air intake manifold was selected due to its significant impact on engine performance and efficiency. A 3D model of the manifold was developed using CATIA software and imported into ANSYS Workbench for simulation. Material properties were assigned, boundary conditions applied, and an internal pressure of 7 bar was used to simulate operating conditions. Fixed supports were applied at the mounting flanges. The analysis focused on key structural outputs: total deformation, equivalent (von Mises) stress, maximum principal stress, and factor of safety, allowing a comparative evaluation of each material's mechanical behavior. Results showed that Aluminium performed reliably with moderate deformation and adequate stress handling. PA6 exhibited slightly higher deformation but remained within acceptable limits, making it viable for medium-performance applications. PP, however, displayed excessive deformation and poor safety margins, suggesting its unsuitability for structural use. CFRP outperformed all other materials, demonstrating minimal deformation, low stress, and the highest safety factor, making it ideal for high-performance and weight-sensitive applications. This study confirms the utility of FEA in optimizing material selection during the early design stages of automotive components. It emphasizes the potential of composites like CFRP to meet modern performance and sustainability goals while offering insights for broader applications in lightweight vehicle design and advanced mechanical systems.