In Formula Student competitions, engines are limited to a maximum capacity of 710cc, coupled with a 19mm diameter intake restrictor that significantly reduces engine power, particularly affecting single-cylinder setups. To maintain competitive performance against multi-cylinder engines without incurring the high costs or logistical challenges associated with upgrading to larger engines, we focused on recovering lost power by upgrading to a turbocharged system.

For our turbocharger selection, we opted for a Variable Geometry Turbo (VGT) due to its efficiency, reduced lag, and compact size, aligning with our goal of achieving 50 hp. After analyzing Garrett turbocharger performance maps, we selected the GT14 model, which operates optimally within our target efficiency zone, enhancing power recovery for our single-cylinder engine.

The turbocharger system was built around the KTM Duke 390 engine. In the FB2020 vehicle, I optimized the intake manifold and exhaust routing to improve airflow efficiency within regulatory limits. I strategically positioned the turbocharger close to the exhaust to minimize energy loss and lower the vehicle's center of gravity, ensuring seamless integration with the existing intake plenum.

The final turbocharged model showcases a streamlined airflow path, with air flowing from the filter through the compressor and intake system, while exhaust gases pass through the turbine to the muffler. This compact design reduces weight and turbo lag, significantly enhancing performance.

A total of 50 hp power was successfully achieved in this project along with 35% torque gains in the operating RPM. Click HERE to see the detailed report.

Naturally Aspirated System of our FB 2020 car

Turbocharged System Assembly in FB 2020 car

Intake Configuration for naturally aspirated engines

Intake Configuration for turbocharged engines

Compressor Map of GT12 C101D

Compressor Map of GT14 C101D

On plotting the points of the compression ratios and mass flow rates onto the compressor maps of the two turbochargers, we found that the operating range of the system was closer to the higher efficiency islands in case of GT14 turbo for the targeted range of 48 hp to 60 hp. Hence, the GT14 turbocharger was selected.

Intake - Velocity particle trace

Exhaust - Velocity particle trace

Naturally Aspirated Engine

Turbocharged Engine

Combined Engine Power - Engine Speed graph: Power Gains

Combined Engine Torque - Engine Speed graph: Torque Gains