18 research outputs found
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Influence of diesel fuel viscosity on cavitating throttle flow simulations at erosive operation conditions
This work investigates the effect of liquid fuel viscosity, as specific by the European Committee for Standardization 2009 (European Norm) for all automotive fuels, on the predicted cavitating flow in micro-orifice flows. The wide range of viscosities allowed, leads to a significant variation of orifice nominal Reynolds numbers for the same pressure drop across the orifice. This in turn, is found to affect flow detachment, formation of large-scale vortices and micro-scale turbulence. A pressure-based compressible solver is used on the filtered Navier-Stokes equations using the multi-fluid approach; separate velocity fields are solved for each phase that share a common pressure. The rates of evaporation and condensation are evaluated with a simplified model based on the Rayleigh-Plesset equation; the Coherent Structure Model is adopted for the sub-grid scales modeling in the momentum conservation equation. The test case simulated is a well reported benchmark throttled flow channel geometry, referred to as ’I-channel’; this has allowed for easy optical access for which flow visualization and LIF measurements allowed for validation of the developed methodology. Despite its simplicity, the Ichannel geometry is found to reproduce the most characteristic flow features prevailing in high-speed flows realized in cavitating fuel injectors. Following, the effect of liquid viscosity on integral mass flow, velocity profiles, vapor cavities distribution and pressure peaks indicating locations prone to cavitation erosion are reported
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Large Eddy Simulation of the internal injector flow during pilot injection
The aim of this work is to simulate the internal flow of a Diesel injector during an entire pilot injection event. In common rail systems a small quantity of fuel can be injected before the main injection is started. This increases the temperature in the combustion chamber and improves the combustion, leading to higher engine efficiency and reduced emissions. The internal nozzle flow during this short event is highly dynamic and vapor cavities may appear at the end of the injection. In order to study the flow characteristics, a numerical methodology based on the Eulerian multi-fluid approach is adopted. The filtered Navier-Stokes equations are discretized with the finite volume method and then solved with an implicit pressure-based solver. The flow field is modelled considering single pressure and velocity fields. The Coherent Structure Model is used to derive the eddy viscosity applied to the Large Eddy Simulation approach. The liquid evaporation rate is evaluated with a cavitation model based on the Rayleigh-Plesset equation for a single bubble. Even though thermodynamic equilibrium is not satisfied a priori, the main parameter is adjusted in order to limit the thermodynamic states to be in a range close to the equilibrium conditions. The liquid compressibility is modelled with a linear correlation between pressure and density variations. The needle longitudinal movement obtained from the experiments is applied to the simulation. The adopted geometry is the Spray A case defined by the Engine Combustion Network. It is an asymmetric single hole Diesel injector that has been extensively studied in the past both experimentally and numerically. The injection pressure is 1,500 [bar] and the ambient pressure is 60 [bar] with a fuel temperature of 363 K inside the injector. Pure n-dodecane is used as fluid in order to have a precise specification of the physical properties. Although both experiments and simulations showed no cavitation for completely open needle at fixed position, recent studies demonstrated that phase-change of the liquid can appear during the needle closing phase. Cavitation erosion prone locations are then evaluated by recording the maximum intensity of pressure on the surface
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Numerical simulation of compressible cavitating two-phase flows with a pressure-based solver
This work intends to study the effect of compressibility on throttle flow simulations with a pressure–based solver.The simple micro throttle geometry allows easier access for obtaining experimental data compared to a real injector, but still maintaining the main flow features. For this reasons it represents a meaningful and well reported benchmark for validation of numerical methods developed for cavitating injector flows.An implicit pressure–based compressible solver is used on the filtered Navier–Stokes equations. Thus, no stability limitation is applied on the time step. A common pressure field is computed for all phases, but different velocity fields are solved for each phase, following the multi–fluid approach. The liquid evaporation rate is evaluated with a Rayleigh–Plesset equation based cavitation model and the Coherent Structure Model is adopted as closure for the sub–grid scales in the momentum equation.The aim of this study is to show the capabilities of the pressure–based solver to deal with both vapor and liquid phases considered compressible. A comparison between experimental results and compressible simulations is presented. Time–averaged vapor distribution and velocity profiles are reported and discussed. The distribution of pressure maxima on the surface and the results from a semi–empirical erosion model are in good agreement with the erosion locations observed in the experiments. This test case aims to represent a benchmark for furtherapplication of the methodology to industrial relevant cases
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Simulation of throttle flow with two phase and single phase homogenous equilibrium model
This paper aims to compare the results of two commonly used methods for the simulation of cavitating flows; one is the two phase mass transfer approach and the other is a homogenous equilibrium model. Both methodologies are compared in a shock tube and a throttle flow, which resembles the constrictions in Diesel injector passages. The mass transfer rate in the two phase model plays the fundamental role in affecting how close to equilibrium the model is; by increasing the mass transfer the two phase model comes close to the homogenous equilibrium model
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Large Eddy Simulation of diesel injector opening with a two phase cavitation model
In the current paper, indicative results of the flow simulation during the opening phase of a Diesel injector are presented. In order to capture the complex flow field and cavitation structures forming in the injector, Large Eddy Simulation has been employed, whereas compressibility of the liquid was included. For taking into account cavitation effects, a two phase homogenous mixture model was employed. The mass transfer rate of the mixture model was adjusted to limit as much as possible the occurrence of negative pressures. During the simulation, pressure peaks have been found in areas of vapour collapse, with magnitude beyond 4000bar, which is higher that the yield stress of common materials. The locations of such pressure peaks corresponds well with the actual erosion location as found from X ray scans
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Evaluation of Turbulence Models Performance in Predicting Incipient Cavitation in an Enlarged Step-Nozzle
Predictive capability of RANS and LES models to calculate incipient cavitation of water in a step nozzle is assessed. The RANS models namely, Realizable k-?, SST k-? and Reynolds Stress Model did not predict any cavitation, due to the limitation of RANS models to predict the low pressure vortex cores. LES WALE model was able to predict the cavitation by capturing the shear layer instability and vortex shedding. The performance of a barotropic cavitation model and Rayleigh-Plesset-based cavitation models was compared using WALE model. Although the phase change formulation is different in these models, the predicted cavitation and flow field were not significantly different
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Performance of turbulence and cavitation models in prediction of incipient and developed cavitation
The aim of this article is to assess the impact of turbulence and cavitation models on the prediction of diesel injector nozzle flow. Two nozzles are examined, an enlarged one, operating at incipient cavitation, and an industrial injector tip, operating at developed cavitation. The turbulence model employed includes the re-normalization group k–ε, realizable k–ε and k–ω shear stress transport Reynolds-averaged Navier–Stokes models; linear pressure–strain Reynolds stress model and the wall adapting local eddy viscosity large eddy simulation model. The results indicate that all Reynolds-averaged Navier–Stokes and the Reynolds stress turbulence models have failed to predict cavitation inception due to their limitation to resolve adequately the low pressure existing inside vortex cores, which is responsible for cavitation development in this particular flow configuration. Moreover, Reynolds-averaged Navier–Stokes models failed to predict unsteady cavitation phenomena in the industrial injector. However, the wall adapting local eddy viscosity large eddy simulation model was able to predict incipient and developed cavitation, while also capturing the shear layer instability, vortex shedding and cavitating vortex formation. Furthermore, the performance of two cavitation methodologies is discussed within the large eddy simulation framework. In particular, a barotropic model and a mixture model based on the asymptotic Rayleigh–Plesset equation of bubble dynamics have been tested. The results indicate that although the solved equations and phase change formulation are different in these models, the predicted cavitation and flow field were very similar at incipient cavitation conditions. At developed cavitation conditions, standard cavitation models may predict unrealistically high liquid tension, so modifications may be essential. It is also concluded that accurate turbulence representation is crucial for cavitation in nozzle flows
Comparison of different techniques for characterizing the diesel injector internal dimensions
[EN] The geometry of certain parts of diesel injectors is key to the injection, atomization and fuel-air mixing phenomena. Small variations on the geometrical parameters may have a strong influence on the aforementioned processes. Thus, OEMs need to assess their manufacturing tolerances, whereas researchers in the field (both experimentalists and modelers) rely on the accuracy of a certain metrology technique for their studies. In the current paper, an investigation of the capability of different experimental techniques to determine the geometry of a modern diesel fuel injector has been performed. For this purpose, three main elements of the injector have been evaluated: the control volume inlet and outlet orifices, together with the nozzle orifices. While the direct observation of the samples through an optical microscope is only possible for the simplest pieces, both Computed Tomography Scanning and the visualization of silicone molds technique have proven their ability to characterize the most complex internal shapes corresponding to the internal injector elements. Indeed, results indicate that the differences observed among these methodologies for the determination of the control volume inlet orifice diameter and the nozzle orifice dimensions are smaller than the uncertainties related to the experimental techniques, showing that they are both equally accurate. This implies that the choice of a given technique for the particular application of determining the geometry of diesel injectors can be done on the basis of availability, intrusion and costs, rather than on its accuracy.This work was partly sponsored by "Ministerio de Economia y Competitividad", of the Spanish Government, in the frame of the Project "Estudio de la interaccion chorro-pared en condiciones realistas de motor", Reference TRA2015-67679-c2-1-R.Salvador, FJ.; Gimeno, J.; De La Morena, J.; Carreres, M. (2018). Comparison of different techniques for characterizing the diesel injector internal dimensions. Experimental Techniques. 42(5):467-472. https://doi.org/10.1007/s40799-018-0246-1S467472425Mobasheri R, Peng Z, Mostafa S (2012) Analysis the effect of advanced injection strategies on engine performance and pollutant emissions in a heavy duty DI-diesel engine by CFD modeling. Int J Heat Fluid Flow 33(1):59–69Dhar A, Agarwal AK (2015) Experimental investigations of the effect of pilot injection on performance, emissions and combustion characteristics of Karanja biodiesel fuelled CRDI engine. Energy Convers Manag 93:357–366Mohan B, Yang W, Chou SK (2013) Fuel injection strategies for performance improvement and emissions reduction in compression ignition engines—a review. Renew Sust Energ Rev 28(x):664–676Petrovic V, Bracanovic Z, Grozdanic B, Petrovic S, Sazhin S, Knezevic D (2015) The design of a full flow dilution tunnel with a critical flow venturi for the measurement of diesel engine particulate emission. FME Trans 43(2):99–106Ilić Z, Rasuo B, Jovanović M, Janković D (2013) Impact of changing quality of air/fuel mixture during flight of a piston engine aircraft with respect to vibration low frequency spectrum. 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Int J Heat Fluid Flow 32(1):273–284Koukouvinis P, Gavaises M, Li J, Wang L (2016) Large Eddy simulation of diesel injector including cavitation effects and correlation to erosion damage. Fuel 175:26–39Som S, Aggarwal SK (2010) Effects of primary breakup modeling on spray and combustion characteristics of compression ignition engines. Combust Flame 157(6):1179–1193Salvador FJ, De la Morena J, MartĂnez-LĂłpez J, Jaramillo D (2017) Assessment of compressibility effects on internal nozzle flow in diesel injectors at very high injection pressures. Energy Convers Manag 132:221–230Salvador FJ, Gimeno J, de la Morena J, MartĂ-AldaravĂ P (2012) Using one-dimensional modelling to analyze the influence of the use of biodiesels on the dynamic behaviour of solenoid-operated injectors in common rail systems: Results of the simulation and discussion. 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June:24–31Payri R, Salvador FJ, Carreres M, De la Morena J (Apr. 2016) Fuel temperature influence on the performance of a last generation common-rail diesel ballistic injector. Part II: 1D model development, validation and analysis. Energy Convers Manag 114:376–391Salvador FJ, Hoyas S, Novella R, Martinez-LĂłpez J (2011) Numerical simulation and extended validation of two-phase compressible flow in diesel injector nozzles. Proc Inst Mech Eng Part-D-J Automob Eng 225(D4):545–563Satkoski C, Shaver G (2011) Piezoelectric fuel injection: pulse-to-pulse coupling and flow rate estimation. IEEE/ASME Trans Mechatron 16(4):627–642Ferrari A, Mittica A (2016) Response of different injector typologies to dwell time variations and a hydraulic analysis of closely-coupled and continuous rate shaping injection schedules. Appl Energy 169:899–911Payri R, Salvador FJ, Gimeno J, De la Morena J (2011) Analysis of diesel spray atomization by means of a near-nozzle field visualization technique. 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Coupled simulations of nozzle flow, primary fuel jet breakup, and spray formation
Presented are two approaches for coupled simulations of the injector flow with spray formation. In the first approach the two-fluid model is used within the injector for the cavitating flow. A primary breakup model is then applied at the nozzle orifice where it is coupled with the standard discrete droplet model. In the second approach the Eulerian multi-fluid model is applied for both the nozzle and spray regions. The developed primary breakup model, used in both approaches, is based on locally resolved properties of the cavitating nozzle flow across the orifice cross section. The model provides the initial droplet size and velocity distribution for the droplet parcels released from the surface of a coherent liquid core. The major feature of the predictions obtained with the model is a remarkable asymmetry of the spray. This asymmetry is in agreement with the recent observations at Chalmers University where they performed experiments using a transparent model scaled-up injector. The described model has been implemented into AVL FIRE computational fluid dynamics code which was used to obtain all the presented results. Copyrigh