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Background
Target for next IC engines generation: contemporary
reduction of fuel consumption and pollutant emissions.
Development and design focused on fuel-air mixing and
combustion:
GDI engines (premixed or stratified)
Diesel engines (complex injection strategies)
New combustion modes (HCCI, PCCI)
CFD widely used for IC engines design:
Development of a platform that can be used both for
model implementation and engine design.
http://www.engines.polimi.it
Topics
Development of new combustion models for IC engines
using the OpenFOAM technology.
Lib-ICE, model development for in-cylinder flow
simulations:
Mesh management
Fuel-air mixing
Combustion
Examples of application on real engine cases
http://www.engines.polimi.it
Lib-ICE
src
Spray
Thermo-physical models
Combustion models
Liquid film
Engine mesh management
Boundary conditions
1D-3D coupling
solvers
Cold-flow
Diesel
Spark-ignition
Combustion
Spray
utilities
Pre-processing
Parallel-processing
Post-processing
Mesh-management
http://www.engines.polimi.it
MESH MANAGEMENT
http://www.engines.polimi.it
Full-cycle simulation
MESH 1
XXX CA
YYY CA
ZZZ CA
MESH 2
4) Mesh-to-mesh interpolation.
http://www.engines.polimi.it
Full-cycle simulation
Automatic mesh motion
Grid points motion computed by an
automatic mesh motion solver, based on
the Laplace equation.
2 u 0
x new xold u t
http://www.engines.polimi.it
Full-cycle simulation
Topological changes
Sliding interface
http://www.engines.polimi.it
Full-cycle simulation
Topological changes: Adaptive Local Mesh Refinement
Mesh management
engine library in Lib-ICE
engine
engineTopoChangerMesh
fvMotionEngineMesh
pistonLayerAREngineMesh
twoStrokeEngineMesh
pistonRefineEngineMesh
multiCycleEngineTime
Compression-expansion with
dynamic mesh layering
Full-cycle simulation in four-stroke
engines
Compression-expansion with
adaptive local mesh refinement
http://www.engines.polimi.it
Full-cycle simulation
Specific utilities for case set-up
1) Generation of multiple meshes
2) Definition of a template case
3) engineCaseSetUp utility
case
case0300
constant
case0320
init
dataOutput
case0720
system
5) Post-processing
case1440
4) runMultiCycleCase
solverName simpleColdSpeciesEngineDyMFoam;
startTimes
(/* list of startTime for each mesh */);
endTimes
(/* list of endTimes for each mesh */);
writeInterval
(/* list of writeInterval for each mesh */);
parallelRun on;
http://www.engines.polimi.it
Full-cycle simulation
Generation of engine meshes
Grid imported from
different tools
(Gambit, ICEMCFD, Pointwise,
STAR-CD)
Fully automatic
hexahedral mesh
generation from stl
file
http://www.engines.polimi.it
Full-cycle simulation
Mesh generation: new approach based on Blender
Blender + snappyHexMesh: engine mesh generation exclusively
based on open-source tools
http://www.engines.polimi.it
Full-cycle simulation
SANDIA Hydrogen Engine (data from ECN)
Displaced volume
560 cm3
Compression ratio
11
Intake pressure/temperature
1 bar / 36 C
Engine speed
1500 rpm
Hydrogen
injector
Fixed zones
Intake
Cylinder
head
Exhaust
Grid size:
Cylinder: 2.5 mm
Valve region: 0.75 mm
Ducts: 2.5 5 mm
Tumble
plate
Laser
532/266 nm
Optical
liner
Piston
Engine
block
http://www.engines.polimi.it
Full-cycle simulation
SANDIA Engine: velocity field comparison
-140 CA
(IVC: -140)
Exp.
Calc.
Full-cycle simulation
SANDIA Engine: velocity field comparison
-70 CA
(IVC: -140)
Exp.
Calc.
Full-cycle simulation
Post-processing
Specific utilities to estimate relevant quantities: charge motions (tumble,
swirl ratio, turbulence intensity); air-fuel mixing: homogeneity index.
Cylinder pressure
0.3
IVC
0.2
0.1
4
0
SOI
EOI
3
-0.1
Tumble ratio
-0.2
-0.3
-0.4
435
465
495
525
555
585
615
645
675
705
735
http://www.engines.polimi.it
http://www.engines.polimi.it
Spray model
Comprehensive spray model for Diesel and GDI sprays
Turbulence
induced
breakup
Wave +
Catastrophic
breakup
Spray model
Comprehensive spray model for Diesel and GDI sprays
Mesh management
dieselSpray library in Lib-ICE
dieselSpray
Partially re-implemented
spray
parcel
Fully re-implemented
spraySubModels
injectorModel
atomizationModel
Huh-Gosman model
wallModel
Bai-Gosman model
breakupModel
Bug fixes
http://www.engines.polimi.it
Liquid film
http://www.engines.polimi.it
Spray model
Non-evaporating diesel spray
Spray model
Evaporating diesel spray (ECN data)
Fuel: n-dodecane (Spray-A)
Effects of ambient conditions (temperature,
density) on liquid and vapor penetration.
http://www.engines.polimi.it
Spray model
Evaporating diesel spray (ECN data)
Fuel: n-heptane (Spray-H)
(b)
(c)
Calc.
Exp.
Distance [mm]
20
30
40
50
http://www.engines.polimi.it
Spray model
Impinging gasoline spray
Liquid film formation on the plate
(a) t = 400 s
(b) t = 2300 s
COMBUSTION MODELS
http://www.engines.polimi.it
Background
Combustion models for IC engines. Requirements:
Flexibility
multiple-injections
stratified charge combustion
different combustion regimes
Detailed chemistry
pollutant formation (soot)
auto-ignition
multi-component fuels
Interacting processes
Energy transfer during spark-ignition
Turbulence-chemistry interaction
http://www.engines.polimi.it
Background
Implementation of combustion models in Lib-ICE
Design-oriented tools:
Fast, robust and suitable for industrial simulations
Reduced chemistry
Diagnostic-oriented tools:
Allowing a detailed analysis of the flame structure
and study of new combustion modes
Detailed kinetics
http://www.engines.polimi.it
COMBUSTION MODELS
Spark-ignition
http://www.engines.polimi.it
http://www.engines.polimi.it
http://www.engines.polimi.it
4rp u st
s plasma
dt
u
dm p
mp
Q spk
Tp Tb
dt
m p
m p c p, p
dTp
http://www.engines.polimi.it
Nf
i Si
i 1
Vcell
http://www.engines.polimi.it
a [m2/s]
Qel
cp [kJ/jkgK]
Temperature [K]
Ti (>10000 K)
Tu (300-600 K)
Temperature [K]
Q el
V t it
a Tpl
a 2Tpl
t
c pV pl
c pV pl
Tpl
http://www.engines.polimi.it
i
t
Vs t is t
s s
R
R
p
Lp
Ls
Spark
gap
dt
2 Es
is t
Ls
Qspk V t i t
http://www.engines.polimi.it
t
xi
xi Sc Sct
P D Pk
xi
Cloud<flameKernel>
particle
electricalCircuit
plasmaChannelModel
sparkIgnitionSubModels
flameSurfaceDensityModels
regionModel
ignition, restrike, wall, dispersion, efficiency
CFM, ECFM, CFM-2, Chang-Huh, ..
Solver: lagrangianPlasmaFlameKernelEngineFoam
http://www.engines.polimi.it
Ignition locations
non-dimensional ratio
16
Calc.
Exp.
12
8
Umean/up
u'/up
0
310
320
330
340
350
360
velocity
Turbulence intensity
http://www.engines.polimi.it
COMBUSTION MODELS
Diesel
http://www.engines.polimi.it
Diesel combustion
Complex process involving:
Detailed fuel chemistry (auto-ignition, pollutant
formation)
Spray evolution
Multi-component fuels
Turbulence-chemistry interaction
Implemented approaches:
Yi a Yi ,Shell 1 a Yi ,CTC
Temperature threshold to switch between auto-ignition (a=1)
and turbulent combustion (a=0).
http://www.engines.polimi.it
85 mm
Stroke
88 mm
Compression ratio
~15
Operating conditions:
Full load with post-injection to reduce soot
Medium high load with:
Variable EGR rate
Three injection events (pre, main, post)
Models:
Modified Huh-Gosman for atomization. Diesel fuel approximated as C12H26
CTC+Shell for combustion. C12H26 Shell-model constants proposed by Reitz.
http://www.engines.polimi.it
0%
EGR
http://www.engines.polimi.it
Measured
Computed
0.9
0.8
0.7
0.6
0.5
0
http://www.engines.polimi.it
2300 rpm
imep = 10.5 bar
100%
0%
EGR
Qpil
Qmain Qpost
http://www.engines.polimi.it
2300 rpm
imep = 10.5 bar
100%
0%
EGR
Qpil
Qmain Qpost
http://www.engines.polimi.it
1
0.8
0.6
Measured
NOx [ppm]
Non-dimensional soot
Computed
0.4
0.2
0
3.5
19.5
23.5
33.5
(std.)
33.5
(adv.)
700
600
500
400
300
200
100
0
Measured
Computed
3.5
19.5
23.5
33.5
(std.)
33.5
(adv.)
Yi t t Yi t
*
t t
Wi
Yi t t Yi t
Yi
t
*
dt '
http://www.engines.polimi.it
chemistryModelPolimi
chemistryModel
chemistrySolversTDAC
mechanismReduction
tabulation
http://www.engines.polimi.it
http://www.engines.polimi.it
OH
Acetylene
BIN1-A
7 mm, exp
12 mm, exp
18 mm, exp
7 mm, calc
12 mm, calc
18 mm, calc
http://www.engines.polimi.it
~
T x
~
~
H x hi Yi x
~
H x
1
~
Z x , Z ''2 x
~
~
Yi x , t f z ; x , t Yi , t d
0
~
Yi Z , t
~st , p
Flamelet
Code
Flamelet Equations
Yi Z 2Yi
Y
2
t
2 Z
hs Z 2 hs
qchem
2
t
2 Z
http://www.engines.polimi.it
f 1
Thermodynamics
Parallelization using existing domain decomposition
techniques.
Pre-implemented functions (average, integration, matrix
algebra) to solve flamelet equations and to exchange data
between the phase space and the physical domain.
http://www.engines.polimi.it
Abstract class
Implementation of Representative
Interactive Flamelet Model
RIF
scalarDissipationRate
scalarDissipationRate
Peters
pdfFunctions
Solver: RIFdieselFoam
http://www.engines.polimi.it
The grid is refined at the boundaries (Z=0, Z=1), to correctly integrate the PDF
function in presence of high mixture fraction variances, as suggested by Liu et al.
http://www.engines.polimi.it
Temperature in
Z-domain
Species
http://www.engines.polimi.it
Temperature in
Cool flame Z-domain
Scalar
dissipation
rate
Species
http://www.engines.polimi.it
Scalar
dissipation
rate
Main ignition
Temperature in
Z-domain
Species
http://www.engines.polimi.it
t = 0.9 ms
Flame
structure in
CFD domain
computed at
steady state
conditions
Mixture fraction
Stoichiometric scalar
dissipation rate
Temperature
http://www.engines.polimi.it
1.2
1.5
Exp.
amb= 14.8 kg/m3
1
0.5
amb= 30 kg/m3
Calc.
0.9
Calc.
Exp.
0.6
0.3
0
12
16
20
24
Oxygen concentration [%]
800
1000
1200
1400
Ambient temperature T [K]
http://www.engines.polimi.it
Acknowledgments