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Experimental and Numerical Studies of Bowl Geometry Impacts on Thermal Efficiency in a Light-Duty Diesel Engine

SAE Technical Papers

Busch, Stephen B.; Zha, Kan Z.; Kurtz, Eric; Warey, Alok; Peterson, Richard

In light- and medium-duty diesel engines, piston bowl shape influences thermal efficiency, either due to changes in wall heat loss or to changes in the heat release rate. The relative contributions of these two factors are not clearly described in the literature. In this work, two production piston bowls are adapted for use in a single cylinder research engine: a conventional, re-entrant piston, and a stepped-lip piston. An injection timing sweep is performed at constant load with each piston, and heat release analyses provide information about thermal efficiency, wall heat loss, and the degree of constant volume combustion. Zero-dimensional thermodynamic simulations provide further insight and support for the experimental results. The effect of bowl geometry on wall heat loss depends on injection timing, but changes in wall heat loss cannot explain changes in efficiency. Late cycle heat release is faster with the stepped-lip bowl than with the conventional re-entrant bowl, which leads to a higher degree of constant volume combustion and therefore higher thermal efficiency. This effect also depends on injection timing. In general, increasing the degree of constant volume combustion is significantly more effective at improving thermal efficiency than decreasing wall heat loss. Maximizing thermal efficiency will require a deeper understanding of how bowl geometry impacts flow structure, turbulent mixing, and mixing-controlled combustion.

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On the Reduction of Combustion Noise by a Close-Coupled Pilot Injection in a Small-Bore Direct-Injection Diesel Engine

Journal of Engineering for Gas Turbines and Power

Busch, Stephen B.; Zha, Kan Z.; Warey, Alok; Pesce, Francesco; Peterson, Richard

For a pilot-main injection strategy in a single-cylinder light-duty diesel engine, the dwell between the pilot- and main-injection events can significantly impact combustion noise. As the solenoid energizing dwell decreases below 200 ls, combustion noise decreases by approximately 3 dB and then increases again at shorter dwells. A zero-dimensional thermodynamic model has been developed to capture the combustion noise reduction mechanism; heat release (HR) profiles are the primary simulation input and approximating them as top-hat shapes preserves the noise reduction effect. A decomposition of the terms of the underlying thermodynamic equation reveals that the direct influence of HR on the temporal variation of cylinder pressure is primarily responsible for the trend in combustion noise. Fourier analyses reveal the mechanism responsible for the reduction in combustion noise as a destructive interference in the frequency range between approximately 1 kHz and 3 kHz. This interference is dependent on the timing of increases in cylinder pressure during pilot HR relative to those during main HR. The mechanism by which combustion noise is attenuated is fundamentally different from the traditional noise reduction that occurs with the use of long-dwell pilot injections, for which noise is reduced primarily by shortening the ignition delay of the main injection. Band-pass filtering of measured cylinder pressure traces provides evidence of this noise reduction mechanism in the real engine. When this close-coupled pilot noise reduction mechanism is active, metrics derived from cylinder pressure such as the location of 50% HR, peak HR rates, and peak rates of pressure rise cannot be used reliably to predict trends in combustion noise. The quantity and peak value of the pilot HR affect the combustion noise reduction mechanism, and maximum noise reduction is achieved when the height and steepness of the pilot HR profile are similar to the initial rise of the main HR event. A variation of the initial rise rate of the main HR event reveals trends in combustion noise that are the opposite of what would happen in the absence of a close-coupled pilot. The noise reduction mechanism shown in this work may be a powerful tool to improve the tradeoffs among fuel efficiency, pollutant emissions, and combustion noise.

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A novel method for correction of temporally- and spatially-variant optical distortion in planar particle image velocimetry

Measurement Science and Technology

Zha, Kan Z.; Busch, Stephen B.; Park, Cheolwoong; Miles, Paul C.

In-cylinder flow measurements are necessary to gain a fundamental understanding of swirl-supported, light-duty Diesel engine processes for high thermal efficiency and low emissions. Planar particle image velocimetry (PIV) can be used for non-intrusive, in situ measurement of swirl-plane velocity fields through a transparent piston. In order to keep the flow unchanged from all-metal engine operation, the geometry of the transparent piston must adapt the production-intent metal piston geometry. As a result, a temporally- and spatially-variant optical distortion is introduced to the particle images. To ensure reliable measurement of particle displacements, this work documents a systematic exploration of optical distortion quantification and a hybrid back-projection procedure that combines ray-tracing-based geometric and in situ manual back-projection approaches. The proposed hybrid back-projection method for the first time provides a time-efficient and robust way to process planar PIV measurements conducted in an optical research engine with temporally- and spatially-varying optical distortion. This method is based upon geometric ray tracing and serves as a universal tool for the correction of optical distortion with an arbitrary but axisymmetric piston crown window geometry. Analytical analysis demonstrates that the ignorance of optical distortion change during the PIV laser temporal interval may induce a significant error in instantaneous velocity measurements. With the proposed digital dewarping method, this piston-motion-induced error can be eliminated. Uncertainty analysis with simulated particle images provides guidance on whether to back-project particle images or back-project velocity fields in order to minimize dewarping-induced uncertainties. The optimal implementation is piston-geometry-dependent. For regions with significant change in nominal magnification factor, it is recommended to apply the proposed back-projection approach to particle images prior to PIV interrogation. For regions with significant dewarping-induced particle elongation (Ep > 3), it is recommended to apply the proposed dewarping method to the vector fields resulting from PIV interrogation of raw particle image pairs.

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Experimental and Numerical Investigations of Close-Coupled Pilot Injections to Reduce Combustion Noise in a Small-Bore Diesel Engine

SAE International Journal of Engines

Busch, Stephen; Zha, Kan Z.; Miles, Paul C.; Warey, Alok; Pesce, Francesco; Peterson, Richard; Vassallo, Alberto

A pilot-main injection strategy is investigated for a part-load operating point in a single cylinder optical Diesel engine. As the energizing dwell between the pilot and main injections decreases below 200 μs, combustion noise reaches a minimum and a reduction of 3 dB is possible. This decrease in combustion noise is achieved without increased pollutant emissions. Injection schedules employed in the engine are analyzed with an injection analyzer to provide injection rates for each dwell tested. Two distinct injection events are observed even at the shortest dwell tested; rate shaping of the main injection occurs as the dwell is adjusted. High-speed elastic scattering imaging of liquid fuel is performed in the engine to examine initial liquid penetration rates. The penetration rate data provide evidence that rate shaping of the initial phase of the main injection is occurring in the engine and that this rate shaping is largely consistent with the injection rate data, but the results demonstrate that these changes are not responsible for the observed trend in combustion noise. A zero-dimensional model is created to investigate the causes of the observed combustion noise behavior. The trend in simulated combustion noise values agree well with the experimentally determined trend, which is associated with two main factors: relative changes in combustion phasing of the pilot and main heat release events and suppression of the pilot apparent heat release for dwell times near the minimum-noise dwell. Two possible mechanisms by which the relative phasing between the pilot and the main heat release events impacts combustion noise are proposed.

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Characterization of Flow Asymmetry During the Compression Stroke Using Swirl-Plane PIV in a Light-Duty Optical Diesel Engine with the Re-entrant Piston Bowl Geometry

SAE International Journal of Engines

Zha, Kan Z.; Busch, Stephen B.; Miles, Paul C.; Wijeyakulasuriya, Sameera; Mitra, Saurav; Senecal, P.K.

Based on the ensemble-averaged velocity results, flow asymmetry characterized by the swirl center offset and the associated tilting of the vortex axis is quantified. The observed vertical tilting of swirl center axis is similar for tested swirl ratios (2.2 and 3.5), indicating that the details of the intake flows are not of primary importance to the late-compression mean flow asymmetry. Instead, the geometry of the piston pip likely impacts the flow asymmetry. The PIV results also confirm the numerically simulated flow asymmetry in the early and late compression stroke: at BDC, the swirl center is located closer to the exhaust valves for swirl-planes farther away from the fire deck; near TDC, the swirl center is located closer to the intake valves for swirl-planes farther away from the fire deck. It is evident from experimentally determined velocity fields that the transition between these two asymmetries has a different path for various swirl ratios, suggesting the influence of intake port flows. Flow field asymmetry can lead to an asymmetric mixture preparation in Diesel engines. To understand the evolution of this asymmetry, it is necessary to characterize the in-cylinder flow over the full compression stroke. Moreover, since bowl-in-piston cylinder geometries can substantially impact the in-cylinder flow, characterization of these flows requires the use of geometrically correct pistons. In this work, the flow has been visualized via a transparent piston top with a realistic bowl geometry, which causes severe experimental difficulties due to the spatial and temporal variation of the optical distortion. An advanced optical distortion correction method is described to allow reliable particle image velocimetry (PIV) measurements through the full compression stroke.

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Principal Component Analysis and Study of Port-Induced Swirl Structures in a Light-Duty Optical Diesel Engine

SAE Technical Papers

Perini, Federico; Zha, Kan Z.; Busch, Stephen B.; Miles, Paul C.; Reitz, Rolf D.

In this work computational and experimental approaches are combined to characterize in-cylinder flow structures and local flow field properties during operation of the Sandia 1.9L light-duty optical Diesel engine. A full computational model of the single-cylinder research engine was used that considers the complete intake and exhaust runners and plenums, as well as the adjustable throttling devices used in the experiments to obtain different swirl ratios. The in-cylinder flow predictions were validated against an extensive set of planar PIV measurements at different vertical locations in the combustion chamber for different swirl ratio configurations. Principal Component Analysis was used to characterize precession, tilting and eccentricity, and regional averages of the in-cylinder turbulence properties in the squish region and the piston bowl. Complete sweeps of the port throttle configurations were run to study their effects on the flow structure, together with their correlation with the swirl ratio. Significant deviations between the flows in the piston bowl and squish regions were observed. Piston bowl design, more than the swirl ratio, was identified to foster flow homogeneity between these two regions. Also, analysis of the port-induced flow showed that port geometry, more than different intake port mass flow ratios, can improve turbulence levels in-cylinder.

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46 Results
46 Results