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SAE TECHNICAL
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2008-01-0973
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2008-01-0973
ABSTRACT
The development of new high power diesel engines is
continually going for increased mean effective pressures
and consequently increased thermal loads on
combustion chamber walls close to the limits of
endurance. Therefore accurate CFD simulation of
conjugate heat transfer on the walls becomes a very
important part of the development. In this study the heat
transfer and temperature on piston surface was studied
using conjugate heat transfer model along with a variety
of near wall treatments for turbulence. New wall
functions that account for variable density were
implemented and tested against standard wall functions
and against the hybrid near wall treatment readily
available in a CFD software Star-CD.
INTRODUCTION
Accurate prediction of the piston surface temperature
and heat flux is difficult mainly because of the very large
temperature and velocity gradients of highly turbulent
flow near the wall and also because of the transient
interaction between the gas phase and solid wall
temperatures. Instead of resolving the temperature and
velocity profiles down to the wall, wall functions based on
some simplifying assumptions of the near wall turbulence
are used. Standard wall functions and hybrid near wall
treatment in the form they are usually implemented in
commercial CFD codes assume incompressible flow.
Therefore straightforward adoption of them into engine
simulations might not be appropriate, since the gas in the
cylinder is highly compressible indeed and large density
variations are likely to appear near the walls. To tackle
this problem momentum and energy equations near the
wall are integrated in their compressible form to new
modified wall functions that are sensitive to density
variation. Also variable turbulent Prandtl number near the
walls is included in the modified wall functions.
Heat transfer in combustion engines has bee widely
studied, e.g. by Schubert, Wimmer and Chamela [1],
who developed quasi-dimensional heat transfer models
for combustion ignition engines, by Han and Reitz [2],
who studied the effect of density variations on convective
heat transfer, by Urip, Liew, Yang and Arici [3], who
studied the effect of unsteady thermal boundary
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( + t ) du = w ,
(1)
dy
dT
= qw .
c p + t
Pr Prt dy
u+ =
T+ =
y w /
u uw
w /
yu f
(2)
(3)
u uw
uf
c p w / (T Tw )
qw
(4)
c p u f (T Tw )
qw
. (5)
t
(y + )
= + =
(y + )3 + 382.5
Prt =
0 .7
+ 0.85
Pr +
(7)
dy +
dy =
u f
(8)
y =
y p w / p
y p u f , p
Equations (1) and (2) are conveniently solved in nondimensional form. In constant density formulation, which
is the basis of the standard wall functions, the nondimensional velocity, temperature and wall distance are
written as
y+ =
(6)
(9)
u f , p = w / p C 4 k p 2
u =
T =
u uw
w / p
u uw
u f ,p
c p , p p u f , p (T Tw )
qw
(10)
(11)
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Tp
y
T
Tp
y + 382.5
T
( y )
=
( y ) + 382.5 (12)
Tp
h=
T p
{ }
1
Pr
+
Pr 0.7 + 0.85 Pr
(19)
T p
c p, p p u f , p
T p as
(20)
(14)
dy
c p , p p u f , p (T p Tw )
(13)
dT =
dy
,
1 +
qw =
0 .7
Prt =
+ 0.85 .
Pr
du =
(15)
u i = u i1 + (Bi + Bi 1 )
is now known
y i
2 ,
(21)
u =0
where Bi is the integrand of eq. (14). Wall shear stress
can be computed from the obtained
u p
i =
Tp
Tw + (T p Tw )y / y
(16)
Ti* = Ti 1 + ( Ai + Ai 1 )
y
2 ,
(17)
T =0
(22)
T p+ =
p c p , p Tw ln (T p / Tw )
qw
( )
y p = 200
i =
u p uw
.
w =
u p
p
T pT
TwT + Ti (T p Tw )
(18)
Tw = 700 K
T p = 1500 K
Pr = 0.7
It can be seen that the laminar and logarithmic curves
*
intersect at y = 10.9577, which is a switching point from
turbulent to laminar law of wall in standard high Reynolds
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18
16
14
T*
8
6
4
2
0
10
10
10
y*
12
11
10
9
Mellor & Kays incompressible
Current formulation
Han & Reitz
6
1
10
10
y
1.8
Laminar
1.7
Turbulent (log)
14
Current formulation
10
18
16
12
T*
Mellor incompressible
Current formulation
Han & Reitz
1.6
Current formulation
12
qw/qw0
1.5
u*
10
1.4
1.3
1.2
1.1
10
10
y
10
0.9
0
10
10
y*
10
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SIMULATION PROCEDURE
COMPUTATIONAL GRID
200
Stroke [mm}
280
510
Displacement [dm ]
8.8
1000
200
15
0.37
1.0
Dodecane, C12H26
2.46
0.5
of
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0.03
0.025
0.02
0.015
0.01
0.005
0
350
355
360
365
370
375
380
385
CA
T ( z , t ) = T0 e z / cos t
2k
=
c p
SIMULATION RESULTS
Maximum piston surface temperature, total piston
surface heat transfer and cylinder pressure were
extracted from all 4 simulations. To avoid
misinterpretation, standard wall functions refer to those
constant density wall functions that are by default in StarCD. The maximum piston surface temperatures are
presented in figure 7. It is noted that the new modified
variable density wall functions (MWF) predict clearly
higher peak temperatures than the other standard (SWF)
and hybrid (HWF) wall functions. This information would
be invaluable when designing pistons for extreme
thermal loads. Total piston heat transfer is presented in
figure 8. The new wall functions also predict higher heat
transfer from the charge to the piston surface as
expected. Cylinder pressures are presented in figure 9.
The new modified wall treatment produces marginally
(approximately 0.2bar) higher peak pressure than the
corresponding simulation with standard wall functions,
which is surprising because more heat is flowing through
the piston with the new wall treatment. However the
relative difference is very small and can be explained by
inspecting the energy balance of the charge gas. In
figure 10 is the cumulative energy difference (heat
release - heat loss through boundaries) between
simulations with the new modified wall treatment and the
standard wall functions. It is noted that while the heat
loss is greater with the new wall treatment, also the heat
release from the burning charge is more rapid. The total
of these is positive between approximately CA 369 and
375, where the pressure also peaks and consequently
the maximum cylinder pressure is higher with the new
modified wall treatment. In figure 11 is a snapshot from
the piston surface temperature distribution and spray at
12 after the TDC, when the piston surface temperature
has its maximum value, approximately 656K. An order of
magnitude comparison can be made with figure 1, where
a same engine was modeled, although the shape of the
piston and running speed were different.
The CPU times of the simulations are listed in table 2.
Simulation with the hybrid wall treatment was the most
time consuming, but it also had a denser mesh than the
other three. There is no big difference between the
standard and RNG k-, but with the new modified wall
treatment the CPU time is increased some 20%. Of
course the increase in the CPU time depends on the
number of points used in numerical integration and the
tightness of the stopping criterion (now 200 and 0.5%).
(24)
11744
10844
k- / HWF / 67500
20109
14186
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1.75
x 10
1.7
k SWF
RNG k SWF
1.65
k HWF
k MWF
1.6
360
364
366
368
370
CA
372
374
376
378
380
400
CA
410
420
430
440
450
50
660
650
Piston surface temperature, Tmax [K]
362
640
k SWF
630
RNG k SWF
k HWF
620
k MWF
610
600
590
580
570
360
380
400
420
440
460
480
500
CA
50
100
150
200
250
350
360
370
380
390
250
k SWF
RNG k SWF
k HWF
200
k MWF
150
100
50
0
355
360
365
370
375
380
385
390
395
400
405
410
CA
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CONCLUSION
To conclude, the new variable density formulation for
wall functions works well and gives reasonable and
expected results compared to constant density wall
functions. That the new variable density wall functions
predict higher heat loss and higher cylinder pressure
simultaneously seems inconsistent, but the difference is
so small that it can be explained by the changes caused
by the new wall functions in turbulent kinetic energy and
dissipation rate that control the reaction rate in the used
EBU LaTCT combustion model. One could do even
better by including the effect of temperature dependent
specific heat capacity to the formulation, but this is left
for future work. However the quality of the modified wall
functions can not be verified without careful comparison
with experimental data, but that is beyond the scope of
this research.
ACKNOWLEDGMENTS
CONTACT
REFERENCES
mika.nuutinen@tkk.fi
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+
dimensionless velocity
kt
Pr
Prt
qw
temperature
Tw
wall temperature
NOMENCLATURE
cp
specific heat
Greek symbols
molecular viscosity
turbulent viscosity
dimensionless temperature
dimensionless
density
temperature
with
uf
friction velocity
uw
reference
dimensionless viscosity t/
density