Thread: NEW JBS ko3 Cast Manifold

JBS K03 Cast Manifold
Over the last couple of months the JBS development team has been busy working on a new cast K03 manifold.
Choosing to cast the new design over tubular was made easier by the design process. Casting the new manifold gives better quality mass production and gives fewer constraints on the pipe bend radiuses, allowing the runner to flow freely. The most obvious improvement being the manipulation of the runner from cylinder 3 into the collector.
The manifold has been designed in CAD to optimise the design, flow capabilities and to enable easier fitment. The CAD process allows the designers at JBS to manipulate the part quickly and while allowing information and measurements to be taken easily, which would be physically impossible to do by hand.


The design initially takes a similar shape to the successful JBS K03 manifold with the runners from cylinders 1, 2 and 4 all being tweaked for the casting process.

The main work has taken place in runner 3 and the box collector to achieve maximum material around the bolt holes to prevent cracking, found on the OEM and competitors manifolds. The collectors design also separates the runners to reduce port sharing of combusted gasses and aiming them towards the turbine in the turbo.
The box collector features cooling fins to minimise the effects of EGT’s on the manifold, preventing the manifold from warping and thermal fatigue.
JBS K03 SPEC


Fitment of the manifold was also a large consideration, the area around the head studs and nuts was maximised especially around the box collector to enable fitment via a double cranked spanner.
The cylinder head flange has been redesigned to allow greater thermal expansion and movement between the runners. The designers found that a too restrictive flange forced stresses back through the runners of the manifold which lead to crack propagation.
Once we were happy with our design it was sent off for rapid prototyping to give us a physical model to evaluate before any design finalisation can take place. The rapid prototype is a highly accurate model taken straight from the CAD data.


The RP (Rapid Prototyping) gives a huge advantage in being able to fit the part to an engine and turbo, to test and ensure that the product achieves its specification. We are also able to physically flow test our design and compare it to our CFD (computational fluid dynamics) data before being sent for casting. The data found from the flow testing has been very interesting. After placing the JBS K03 manifold against current products on market we found the JBS manifold not only flows a considerable amount more as a manifold but also due to the complex design and hours spent in CFD individual runner , balance, and flow were significantly increased.




JBS has chosen to cast its manifolds in a very high quality UK based foundry which is used by the likes of Borg Warner and many other OEM turbo suppliers to ensure the castings are of the highest quality. To reflect the high quality casting, we have chosen the same material as the hot side of the turbochargers D5S ni-Resist is a cast irons with high nickel content has the following properties: resistance to corrosion, resistance to oxidisation and high temperatures, resistance to wear and erosion. This is to ensure a minimal amount of thermal expansion and an equal rate of thermal expansion to the turbo housing, this again minimises the potential for thermal fatigue. The bolts for the fitment of the turbo to the manifold shall be supplied as they are a specific size and material to prevent stretching which leads to blowing gaskets.
Once the first batch of manifolds are produced, they shall be thoroughly tested and dyno’d. At which time all power and flow figures will be released. Once all testing is completed and we are happy with the results we aim to release the manifolds at £380 including bolts and VAT.
We also have an IHI stage one/ Garrett GT28 cast manifold going into production with the new ko3 manifold. As well as having K04 and Twin Scroll manifolds going through our design process and rigorous testing and hope to be able to bring them to you as soon as possible.
JBS Team

JBS Auto Designs Cast OEM Upgrade Manifolds: Another step closer

From our last update things have moved on.

JBS Developments has now received the first preproduction sample for the K03 OEM performance upgrade manifold.






JBS Developments has been looking for a foundry that can offer not only the high quality product and finish expected but also the material choice needed to ensure the best performance from the manifolds.

Recently there has been a lot of talk about performance manifolds cracking due to poor design, weak materials and the stress the manifolds are under due to high exhaust gas temperatures. JBS Developments are confident in the design of the new manifolds due to the hours spent on CFD (computational fluid dynamics) analysis and prototyping.

So to ensure the manifolds don’t suffer from poor material choice and casting quality, JBS has chosen to cast its manifolds in a very high quality foundry which is used by many OEM turbo suppliers and OEM vehicle manufacturers to ensure the castings are of the highest quality.

Also to reflect the high quality casting; JBS has spent a great deal of time researching the latest high temperature resistant cast irons. These cast irons have a high nickel content, having the following properties makes them ideal for our performance manifolds: resistance to corrosion, resistance to oxidisation and high temperatures (up to 1050 oC), resistance to wear and erosion.

This is to ensure a minimal amount of thermal expansion and an equal rate of thermal expansion to the turbo housing, this again minimises the potential for thermal fatigue (cracking). The bolts for the fitment of the turbo to the manifold shall be supplied as they are a specific size and material to prevent stretching which leads to blowing gaskets.






Now we have the sample we can physically test our design and compare it to our CFD data from the prototype and CAD analysis.

JBS Developments is expecting the manifold not only flows a considerable amount more than the OEM manifold but due to the complex design and hours spent in CFD analysis on individual runner balance and flow, to give a significant increase over any other manifold available.

JBS Developments

Very nice, I assume they are for transverse engines only?

Originally Posted by Byzan A4

Very nice, I assume they are for transverse engines only?

Yes, this K03 upgrade is for transverse engines only, as the demand has been higher for such an upgrade.

Once we have put more manifolds into production we will be able to provide other engine options.

With the release of the k03 and soon the transverse K04 manifolds we are testing our designs and processes as we are new to production of this scale. Once these manifolds have been through production it will be alot easier for us to develop new manifolds.

JBS Developments

JBS K03

Now we have received our first pre-production sample we have started testing it.

Initially we have flow bench tested it against a standard OEM K03 manifold.
The testing was carried out on a Superflow SF-120 Flow bench, which is an industry favoured bench for testing engines up to 100 Hp (75 kW) per cylinder.

The SF-120 has built in flow bench swirl meter, 4 valve universal opener with dial gauge, exhaust velocity pitot tube, inlet velocity pitot tube and specific cylinder head adaptor, making it the ideal machine to test our new manifold designs.



The manifolds were tested on the flow bench with a AUQ 1.8 20v Turbo head with no valves. To keep the flow data accurate for each runner the flow was simulated with the appropriate head valves open and closed.

The flow was tested through the most optimum runner, which is usually the longest (for the K03 this is runner 1) and through the shortest runner (runner 3 on both manifolds). Using these 2 runners shows the flow range of the manifold and gives the most usable results.

Results

Test Data:
Head: AUQ 5v
Depression: 10” @ 12 deg C temp correction
K03 OEM Cast Manifold



JBS K03 OEM Upgrade Manifold







Conclusion

JBS Developments main aim when starting to develop the new K03 upgrade manifold was to produce a manifold that not only performed better than anything else on the market but that was also more reliable.

From the results it’s clear that in ideal conditions the JBS K03 Cast manifold gives a 50% flow increase in CFM throughout the runners.


Developing an upgrade manifold for the K03 is not only about high flow and big power figures, but about how the manifold reacts to the environment. Performance manifolds tend to crack due to weak materials and the stress the manifolds are under due to high exhaust gas temperatures caused by poor design.

So with hours spent in CFD analysis on individual runner balance and flow to ensure the flow of the exhaust gas doesn’t affect the manifolds structure along with extensive research into the latest high temperature resistant cast irons to combat the high exhaust gas temperatures. The new upgrade manifold will be more reliable and more efficient. Whilst being able to withstand high exhaust gas temperatures means that higher boost levels will be achievable, it also means that due to better flow properties the manifold will have lower EGT’s and therefore be more reliable.

The next set of tests to be carried out will be on the rolling road, with a standard K03 turbo and a hybrid, so we can see the overall increase in boost, EGT’s and spool times, as well as see the true top end capabilities of the manifold.

The Manifolds have arrived today.

They have all been inspected and checked.




All the pre-order manifolds will be sent out tomorrow.

With all the manifolds being on general sale by the weekend.

Buy here:
http://www.jbsautodesigns.co.uk/prod...03-oem-upgrade

Regards
JBS Sales