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Intake manifolds have an important function on pollutants emission, which physical characteristics like regular air pressure loss and difference among runners are some factors that influences on performance and fuel consumption. To a fast development of new intake manifolds which find current targets, is necessary to use computational methods. In this case CFD was used to reduce some intermediate prototypes. However it is mandatory consider that models need adjustment and correlation with actuality to be good tools. This paper shows numeric simulations and experimental results from some manifolds, correlating and validating about several features, attributing so some confidence to model.

This paper refers to a developed measurement process able to interact with small plastic parts, with holes about 0.4mm of diameter with a critical function on the vehicle. This method must be similar to the real condition. In other words, it must represent the fuel passing through these parts, though in a clean and faster way. To do this characterization, a light beam was used, in intensity strong enough to pass from side to side of the cavity up to the hole. This way enabling us to measure the light intensity that goes out. The resultant spread light beam is recorded by a digital microscope and converted in a chart by an algorithm. Based on a model developed, that picture is converted or translated in a number which can be used to separate part types, according to correlation of the spray performances. The main purpose of this methodology is a simple and effective way to monitor the produced parts and ensure the proper operation of the component when assembled in the complete system.

The following article describes a method developed to control the ultrasonic fuel rail welding. It is done monitoring some physical phenomena during the process, like vibration amplitude, welding energy and its duration. Based on statistical analysis, durability and aging tests on a great population of manufactured parts, it was possible to classify those parameters and build a real time filter capable to segregate bad parts in less than one second, just after process is done. This way, it is possible to purge the bad parts before spending more time and resources in a nonconforming segment.

In this paper an intake manifold has its performance evaluated as a SLS technique rapid prototype and the final plastic molded product. The main difference between these manufacturing methods is the surface's roughness. A comparison of the flow characteristics from both is performed through air flow bench testing. These components were also tested in engine dynamometer, having its performance evaluated in a real engine.