Ford EPD/CFD Prototype Analysis
Since 2003, utilizing Twin Scroll turbo systems for high-performance track racing is how Full-Race staked our global on-track reputation. The following photo shows a Full-Race Twin Scroll Turbo Manifold on the left (divided flange) and a single scroll on the right (undivided open flange).
Full-Race was approached by Ford powertrain engineers and BorgWarner Director of New Technologies, with the concept of prototyping a high performance 4cylinder EcoBoost engine turbo kit. Full-Race was asked to build (2) prototype turbo systems which could be CFD analyzed then tested in Ford’s Engine lab – we jumped at the opportunity. Work began on a 2.0L Classic engine, while detailed testing in the lab took place with a new prototype 2.3L engine. One of the prototypes we built was a traditional “single scroll” tubular equal length manifold, and the other our signature “twin scroll” design. The Ford Powertrain team loved our “twin scroll prototypes”, which proved extremely successful – scoring an average gamma value of 96% on these custom 2.3L prototype development lassic” motors, compared to only 78% found on the traditional single scroll configuration with the same engine. The results were mind blowing. The following Images show the details of our testing:
FORD EPD/ CFD Prototype Analysis Photos
Full-Race Single Scroll vs Twin Scroll Turbo Configuration
|SINGLE SCROLL||VS||TWIN SCROLL|
Gamma (Flow Uniformity) Conclusions
|Singlescroll Gamma = 0.85||Twinscroll Gamma = 0.96||Overlay Singlescroll (Red) vs Twinscroll|
When looking at the overlay comparison, it’s easy to see that the twin scroll system maintains a much higher “Gamma” score, never dropping below 90%. However, the Single scroll configuration allows for a considerable drop in Flow uniformity, touching into the 70% range between every combustion event. This comprehensive CFD analysis was a success for all teams involved, showing a vastly superior Gamma score for the Full-Race twin scroll turbo configuration. Fast-forward to June 2011 where it was time to finally test on the prototype engine in the real world.
Ford On-Engine 2.3L Full-Race Twin Scroll Prototype Testing: Ford engineers successfully built a 2.3L prototype engine on which they could implement and fully test this twin scroll system – for real, on an engine-dyno. Using a special camshaft to drive an F150 EcoBoost GDI fuel pump, the fueling was in place for our target of 300hp/300tq with full boost by 2000rpm for a v8-like powerband.
The end result saw these targets were not only achieved, but surpassed – with 325 horsepower and 350ft-lb Torque realized under a conservative tune on pump gasoline.
Ford’s decision to integrate the 2.3L Mustang Ecoboost’s twin scroll system into a unique dual-exhaust-port cylinder head configuration design is not only ideal for OEM performance targets, but also makes for efficient and cost-effective aftermarket engine boosting options.