a numerical investigation on the potentials of water injection to increase knock resistance and reduce fuel consumption in highly downsized gdi engines

Abstract 3D CFD analyses are used to analyse the effects of port-injection of water in a high performance turbocharged GDI engine. Particularly, water injection is adopted to replace mixture enrichment while preserving, if not improving, indicated mean effective pressure and knock resistance. A full-load / maximum power engine operation of a currently made turbocharged GDI engine is investigated comparing the actual adopted fuel-only rich mixture to stoichiometric-to-lean mixtures, for which water is added in the intake port under constant charge cooling in the combustion chamber. In order to find the optimum fuel/water balance, preliminary analyses are carried out using a chemical reactor to evaluate the effects of charge dilution and mixture modification on both autoignition delays and laminar flame speeds. Thanks to the lower chemical reactivity of the diluted end gases, the water-injected engine allows the spark advance (SA) to be increased; as a consequence, engine power target is met, or even crossed, with a simultaneous relevant reduction of fuel consumption

Two-Stage Turbocharging for the Downsizing of SI V-Engines

AbstractOne of the most critical challenges for the specific power increase of turbocharged SI engines is the low end torque, limited by two aspects. First, the big size of the compressor necessary to deliver the maximum airflow does not allow high boost pressures at low speed, due to the surge line proximity. Second, the flame front velocity may become slower than the end gas auto-ignition rate, thus increasing the risk of knocking.This study is based on a current SI GDI V8 turbocharged engine, modeled by means of CFD tools, both 1d and 3d. The goal of the activity is to lower by 20% the displacement, without reducing brake torque, all over the engine speed range.It was decided to adopt a smaller bore, keeping stroke constant. Obviously, the combustion chamber, the valves and the intake-exhaust ports have been re-designed, as well as the whole intake and exhaust system. Instead of the two turbochargers, one for each bank of cylinders, a triple-turbocharger layout has been considered.The development of the engine has been carried out by means of 1D engine cycle simulations, using predictive knock models, calibrated with the support of both experiments and CFD-3d simulations. A few operating conditions for the final configuration have been also analyzed by means of a 3-d CFD tool.The paper presents the results of this activity, and describes in details the guidelines followed for the development of the engine

Effects on Knock Intensity and Specific Fuel Consumption of Port Water/Methanol Injection in a Turbocharged GDI Engine: Comparative Analysis

Abstract The recent rise in fuel prices, the need both to reduce ground transport-generated emissions (increasingly constrained by legislation) and to improve urban air quality have brought fuel-efficient, low-emissions powertrain technologies at the top of vehicle manufacturers' and policy makers' agenda. To these aims, engine design is now oriented towards the adoption of the so-called downsizing and down-speeding techniques, while preserving the performance target. Therefore, brake mean effective pressure is markedly increasing, leading to increased risks of knock onset and abnormal combustions in last-generation SI engines. To counterbalance the increased risks of pre-ignition, knock or mega-knock, currently made turbocharged SI engines usually operate with high fuel enrichments and delayed (sometimes negative) spark advances. The former is responsible for high fuel consumption levels, while the latter induce an even lower A/F ratio (below 11), to limit the turbine inlet temperature, with huge negative effects on BSFC. Possible solutions to increase knock resistance are investigated in the paper by means of 3D-CFD analyses: water, water/methanol emulsion and methanol are port-fuel injected to replace mixture enrichment while preserving, if not improving, indicated mean effective pressure and knock safety margins. The aim of the work is therefore the replacement of the gasoline-only rich mixture with a global stoichiometric one while avoiding power loss and improving fuel consumption. In order to maintain the same knock tendency, water, methanol or a mixture of the two is then added in the intake port to keep the same charge cooling of the original rich mixture. Different strategies in terms of methanol/water ratios of the port injected mixture are compared in order to find the best trade-off between fuel consumption, performance and knock tendency

Numerical investigation on the effects of bore reduction in a high performance turbocharged GDI engine. 3D investigation of knock tendency

Abstract Downsizing is a must for current high performance turbocharged SI engines. This is often achieved through the reduction of cylinder number, while keeping constant unit displacement and increasing boost pressure. However, the ensuing higher loads strongly increases the risk of abnormal combustion and thermo-mechanical failures. An alternative path to downsizing is the reduction of cylinder bore: this approach is more expensive, requiring a brand new design of the combustion system, but it also provides some advantages. The goal of the present paper is to explore the potential of bore reduction for achieving a challenging downsizing target, while preserving the engine knock safety margins. A current V8 GDI turbocharged sporting engine is taken as a reference, and a preliminary CFD-3D analysis is carried out in order to define the most suitable bore-to-stroke ratio. On this basis, bore is reduced by 11% at constant stroke, thus obtaining a reduction of about 20% on the engine displacement. In order to achieve the same peak power target, both engine boost and spark advance are adjusted until the knock safety margin of the original engine is met. 3D CFD tools, accurately calibrated on the reference engine, are used to address engine design and the calibration of the operating parameters

LES Modelling of Spark-Ignition Cycle-to-Cycle Variability on a Highly Downsized DISI Engine

The paper reports an activity aiming at characterizing cycle-to-cycle variability (CCV) of the spark-ignition (SI) process in a high performance engine. The numerical simulation of spark-ignition and of early flame kernel evolution are major challenges, mainly due to the time scales of the spark discharge process and to the reduced spatial scales of flame kernel. Typical mesh resolutions are insufficient to resolve the process and a dedicated treatment has to be provided at a subgrid level if the ignition process is to be properly modelled. The focus of this work is on the recent ISSIM-LES (Imposed Stretch Spark-Ignition Model) ignition model, which is based on an extension of the flame surface density (FSD) transport equation for a dedicated flame kernel treatment at subgrid scales. The FSD equation is solved immediately after spark discharge. The interaction of the flame kernel with the flow field is fully accounted for since spark formation and a transition is provided from ignition to propagation phase. The comparison is carried out with the AKTIM-Euler ignition model in terms of flame interaction with the flow field (e.g. arc convection, flame blow-off, flame holder effect). A multiple cycle LES activity provided a set of cycle-resolved conditions for spark-ignition comparisons, and the flame kernel development is carefully analyzed for the two ignition models on a wide range of thermo-physical conditions. Spark-ignition cyclic variability and combustion traces are compared with experiments. Results confirm that the simulated cycle-to-cycle variability increases through the adoption of the ISSIM-LES ignition model

Understanding the origin of cycle-to-cycle variation using large-eddy simulation: Similarities and differences between a homogeneous low-revving speed research engine and a production DI turbocharged engine

A numerical study using large-eddy simulations (LES) to reproduce and understand sources of cycle-to-cycle variation (CCV) in spark-initiated internal combustion engines (ICEs) is presented. Two relevantly different spark-ignition (SI) units, that is, a homogeneous-charge slow-speed singlecylinder research unit (the transparent combustion chamber (TCC)-III, Engine 1) and a stratifiedcharge high-revving speed gasoline direct injection (GDI) (Engine 2) one, are analyzed in fired operations. Multiple-cycle simulations are carried out for both engines and LES results well reproduce the experimentally measured combustion CCV. A correlation study is carried out, emphasizing the decisive influence of the early flame period variability (1% of mass fraction burnt (MFB1)) on the entire combustion event in both ICEs. The focus is moved onto the early flame characteristics, and the crucial task to determine the dominant causes of its variability (if any) is undertaken. A two-level analysis is carried out: the influence of global parameters is assessed at first; second, local details in the ignition region are analyzed. A comparison of conditions at combustion onset is carried out and case-specific leading factors for combustion CCV are identified and ranked. Finally, comparative simulations are presented using a simpler flame deposition ignition model: the simulation flaws are evident due to modeling assumptions in the flame/flow interaction at ignition. The relevance of this study is the knowledge extension of turbulence-driven phenomena in ICEs allowed by advanced CFD (Computational Fluid Dynamics) simulations. The application to different engine types proves the soundness of the used models and it confirms that CCV is based on enginespecific factors. Simulations show how CCV originates from the interplay of small- and large-scale factors in Engine 1, due to the lack of coherent flows, whereas in Engine 2 the dominant CCV promoters are local air-to-fuel ratio (AFR) and flow velocity at ignition. This confirms the absence of a generally valid ranking, and it demonstrates the use of LES as a development and designorienting tool for next-generation engines