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1
MODELS The effective flow area is calculated by multiplying the
geometric area by the discharge coefficient, Cd, which is
FUEL RATE MODEL – The flow dimensioning areas in calculated with the following expression [4]:
the flow path in the nozzle are the truncated cone shaped for
area between the needle and the needle seat and the
hole area. The geometry of the former varies with the
needle lift.
(Eq. 3)
(Eq. 4)
Where:
L is the length of the hole or the valve seat [m].
D is the hydraulic diameter of the hole or the valve seat
[m]. For the holes, D is the nominal hole diameter multi-
plied by the correction factor: CorrD .
CD
Re is the Reynolds number, i.e. Re = , where:
C ν
is the speed of the flow [m/s]
ν is the kinematic viscosity [m2/s]
The pressure drop across the valve seat is given by:
ρ × Ccone
2
Pinj − Psac =
2 (Eq. 5)
Figure 1. Flow paths in a nozzle [6]
The pressure drop across the holes is given by:
The mantel surface area of the truncated cone can be
calculated by using the following parameters shown in ρ × C holes
2
Psac − Pcyl =
Figure 1 where: 2 (Eq. 6)
H is the needle lift
Where:
R is the base circle radius of the truncated cone Pinj is the injection pressure [Pa]
α is half the tip angle of the needle Psac is the pressure in the sac [Pa]
By using standard geometrical relationships it can be Pcyl is the pressure in the cylinder [Pa]
shown that the truncated cone area, i.e. the flow area
between the needle and the seat, can be expressed in Ccone is the speed through the valve seat [m/s]
the following way: Choles is the speed through the holes [m/s]
Acone = π [2 R − H sin(α ) cos(α )]H sin(α ) ρ is the density of the fuel [kg/m3]
(Eq. 1)
Due to the incompressibility of the fuel the mass
The total area of the holes is not varied and is given by
the following expression: flow through the valve se m& cone
at,, and the holes,
m& holes , is assumed to be equal:
Aholes = N holes × π × (CorrD × Dholes ) 2 × 0.25
(Eq. 2) m& cone = ρ × Ccone × Cd cone × Acone
(Eq. 7)
Where:
N holes is the number of holes. [-] m& holes = ρ × Choles × Cd holes × Aholes
(Eq. 8)
Dholes is the diameter of the holes. [m] m& cone = m& holes
(Eq. 9)
CorrD is a correction factor for the hole diameter. [-]
2
The calculated injected fuel mass per injection, Table 1. Test conditions and input for calculations
DeltaCalc , is given by the following expression:
t EOI
DeltaCalc = ∫ m&
ta
holes (t )dt
(Eq. 10)
Where:
tα is the time at start of injection [s]
t EOI is the time at end of injection [s]
The injection pressure and the pressure in the cylinder
are given at every time step of calculation. The pressure
in the sac is calculated by iteration where the speeds,
Reynolds numbers and discharge coefficients at the seat
and the holes are calculated. The needle lift is also given
at every time step and thus the mantel surface area of the
truncated cone can be calculated. Dholes is the nominal hole diameter
When the areas of the flow paths, the corresponding dis- Hmax is the maximum needle lift
charge coefficients, the flow speeds and the densities are
given, the mass flow, i.e. the flow rate, can be calculated C1000 is the plunge speed at 1000 rpm
using equations (7) or (8). Delta is the measured mass of fuel injected at each
cycle
Model Verification – The fuel rate model was verified by
comparing calculated and measured accumulated fuel CorrD1 is the correction factor for Dholes to get the mea-
flow data. The measurements were performed on a sin- sured fuel mass when using the model. See equation (2).
gle cylinder supercharged heavy-duty diesel engine with CorrD2 is the correction factor for D holes to get the mea-
a displacement of two liters. The compression ratio was sured fuel mass when using the model while keeping
18:1 and a unit injector system was used. During the test Cdcone=1.
series, consisting of 6 runs, the engine speed was kept
constant at 1200 rpm. The fuel pressure, the cylinder When using the nominal hole diameter the accumulated
pressure and the needle lift were recorded during the fuel mass, i.e. Delta, is underestimated with the flow
test. The following input to the calculations was kept con- model at all runs. There are many possible reasons for
stant at all runs: this, one being that the holes are somewhat bigger in
reality than the nominal diameter. The variable Corr D1
R = 0.6e-3 [m] represents the increase of the hole diameter necessary
α = 47.5 [o] to get the measured fuel mass when using the flow
model. The figures correspond quite well with the upper
Nholes = 6 [-] manufacturing tolerance of the holes.
Dcone = half the gap between the needle and the seat Another explanation is that the discharge coefficient of
Lholes = 0.6e-3 [m] the valve seat, i.e. Cdcone, is under-estimated. With the
given input, the value is close to 0.8 at maximum flow. As
Lcone = 0.01e-3 [m] the flow path in the gap is constantly narrowing it is possi-
ν = 3.0e-6 [m2/s] ble that the contraction of the flow is much less. For that
reason the fuel flows were recalculated with the assump-
ρ = 840 [kg/m3] tion that Cdcone = 1. It was then found that the model
The test variables are shown in Table 1 below. IP stands overpredicted the flow and, in order to get agreement
for Input and refers to the run number. with measured data, a correction factor that reduced the
hole diameters was introduced. This factor CorrD2 for the
different nozzles is also shown in Table 1.
Since the fuel flow model does not include any pressure
loss due to turbulence in the sac, it is very likely that the
discharge coefficient of the valve seat is closer to 1 than
the model predicts. Some typical calculated results from
the flow model are shown in the Figures below. Cdcone =
1 and CorrD2 is used when generating the curves.
3
Figure 2. Cylinder, Injection and Sac Pressures vs CAD.
IP 1 Figure 4. Accumulated injected fuel mass versus CAD.
IP 1
Figure 2 shows the measured injection and cylinder pres-
sures and the calculated sac pressure. As can be seen, The conclusions from using the fuel flow model are that
the sac pressure is close to the cylinder pressure at the the discharge coefficient at the valve seat is probably
first crank angles when the needle is opening, e.g. the underestimated and that the pressure loss due to turbu-
flow is mainly controlled by the valve seat area. It can lence in the sac should be accounted for in order to get
also be seen that injection pressure falls rapidly and even better agreement with measured data.
below cylinder pressure at the end of injection. As will be
shown in the next figure, this results in a negative fuel HEAT RELEASE RATE (HRR)- FUEL RATE (FR)
flow which is not likely to happen. The reason is a bump MODEL – When examining different experimental cases
in the needle lift curve. where the HRR and FR were calculated it, was observed
that the following equation gave a reasonable relationship
between the two rates:
dQ = k (Q fuel − Q)
(Eq. 11)
Where:
dQ is the heat release rate, HRR, [W]
Q is the accumulated released heat, HR, [J]
Q fuel
is the energy of the accumulated injected fuel [J]
k is an empirical constant [1/s]
The fuel energy can be expressed in the following way:
t
Q fuel = H u ∫ m& (t )dt
tα
(Eq. 12)
Figure 3. Calculated injected fuel flow. IP 1 Where:
Hu
The last two figures, 3 and 4, show the calculated fuel is the lower heating value of the fuel [W/kg]
flow and accumulated fuel mass during the injection m& is the fuel rate [kg/s]
period. The star in Figure 4 shows the measured fuel tα
mass, i.e. Delta. The correction factor Corr D2 was varied is the time at start of injection [s]
until the Delta and the calculated fuel mass, DeltaCalc, t is the time of the calculation step in question [s]
agreed. In this particular case, e.g. IP=1, the value of the
correction factor was found to be 0.956. This means that
the nominal hole diameter had to be reduced by 4.4%.
4
Figure 5. Measured and calculated HRR. IP 1 Figure 8. Measured and calculated HRR. IP 4
Figure 6. Measured and calculated HRR. IP 2 Figure 9. Measured and calculated HRR. IP 5
Figure 7. Measured and calculated HRR. IP 3 Figure 10. Measured and calculated HRR. IP 6
5
The interpretation of equation (11) is that the HRR is pro- turbulence. Heat release rates for different values of k are
portional to the mass of injected fuel not yet combusted shown in Figure 11 below.
in the cylinder. The figures above show the results of
HRR calculations based on the fuel rate calculations dis-
cussed above, i.e. based on input data given in Table 1
and in the text below the table.
The net portion of the “measured” HRR, Qn ,is calculated
with an expression derived from the first law of thermody-
namics. Any effects of blowby, crevices and the enthalpy
of the injected fuel are neglected.
dQn γ dV 1 dp
= p + V
dt γ − 1 dt γ − 1 dt (Eq. 13)
Where:
Qn
is the net heat release [J]
γ is the ratio of specific heats [-]
p is the pressure [Pa]
Figure 11. The influence on calculated HRR of the
V is the volume [m3] constant k. The curves correspond to k values:
100, 300, 500, 1000, 1500, 2000 and 3000.
The ratio of specific heats is calculated by using the
actual fluid composition according to the multi-zone
The Fuel Rate to Heat Release Rate model does not
model used. The method is thoroughly described in [3].
include any ignition delay calculations at the moment.
The heat transfer is calculated with the standard expres- This means that the heat release is assumed to start as
sion for convective heat transfer, i.e.: soon the fuel enters the cylinder. Or, if the heat release is
given, the fuel injection starts at the time of combustion
dQht initiation. This weakness of the model does not play any
= hc × Areawall (Tgas − Twall ) important role when the ignition delay is short, as it was
dt (Eq. 14) in the cases studied. If, however, the model should be
Where: used in combustion cases with long ignition delays, it
Qht must include a submodel for the delay.
is the heat transferred to the wall by convection
[J] NO CALCULATION – The model used for NO calculation
hc is the heat transfer coefficient [W/K m2] is described in depth in [3]. Basically it is a multizone
Areawall is the area of the wall [m2] combustion model where the HRR is used as input. At
every time step of calculation the amount of air and fuel
Tgas that corresponds to the released heat during the step in
is the temperature of the gas [K]
Twall question is combusted in a simple combustion model.
is the temperature of the wall [K] The local temperatures are determined by minimizing
The heat transfer coefficient hc is calculated by the Gibb’s free energy. NO formation in the combustion and
expression proposed by Woschni as presented in [7]. post combustion zones is calculated with the Zeldovich
mechanism.
The sum of Qn and Qht is the gross heat release which is
the quantity labeled “measured” in the previous figures. The combustion and post combustion zones could be
divided into different subzones with different assumed
Different values of the empirical constant k in equation equivalence ratios. In this work, however, it is assumed
(11) were tested, and it was found that k=500 [1/s] gave that the combustion influencing the NO formation takes
reasonable agreement with the HRR derived from the place at an average equivalence ratio close to one (1.05).
cylinder pressure measurements. Thus, this value was This ratio was found when comparing calculated and
used in the calculation of the results shown in the figures measured NO emissions. Another assumption in the
above. model is that the post combustion zones do not mix with
The constant k can be interpreted as a spray or atomiza- other zones or the fresh charge as long as the NO forma-
tion characteristic number. The higher the value of k the tion continues.
smaller the droplets and the better the penetration, i.e.
factors that control the rate of combustion. For a given
spray k can probably be related to the swirl ratio or the
6
VIBE FUNCTION REPRESENTATION OF HRR – Vibe Table 2. Input to the HRR shown in Figures 12 and 13
functions are frequently used to describe the heat below
release in IC engines. In this model the sum of two Vibe
functions is used to represent the heat release in a diesel
engine. The first describes the premixed and the second
the diffusive part of the heat release.
A Vibe function has the general form:
m +1
Θ − Θ0
X (Θ) = 1 − exp(−a )
∆Θ (Eq. 15)
Where:
X (Θ ) is the fraction of the total released heat at
CAD Θ [-]. The figure below shows the contribution of the premixed
HRR and the diffusive HRR on the total heat release rate,
Θ0 is the crank angle at which the heat release
dQ. The input is chosen to get a reasonable correspon-
dence to a measured HRR curve. This is shown in Figure
starts [CAD]. 13 below. The proportions between the energy released
at premixed and diffusive phases of combustion are not
correlated to the fuel flow during the actual ignition delay
∆Θ is the duration of the heat release [CAD]. time.
a and m are constants [-]
By using Vibe functions for the premixed and the diffusive
stages of combustion, the total released heat can be rep-
resented by the following expression:
Q (Θ )= Q tot [ X (Θ ) + k X ( Θ )] /( k + 1)
diff frac pm frac
(Eq. 16)
Where:
Q(Θ) is the released heat at crank angle [J] Θ
Qtot is the released heat at the end of combustion [J]
X diff (Θ)
is the value of the Vibe function for the
Θ
diffusive released heat at crank angle [-]
X pm (Θ) is the value of the Vibe function for the
premixed released heat at crank angle [-]
k frac Figure 12. Typical HRR curve generated with Vibe
is the premixed heat release fraction of the
functions
released heat by diffusive combus-tion at the end of com-
bustion. [-]
Separating the two combustion modes could be impor-
A typical HRR for a diesel engine generated with Vibe tant when looking at NO formation. According to [1] the
functions is shown in Figures 12 and 13 below. The fol- premixed combustion takes place at such a high equiva-
lowing input was used: lence ratio that NO formation is not likely to occur. As can
be seen inTable 2 and Figure 12, the premixed and diffu-
sive combustion phases are slightly overlapping (0.7
CAD). Experiments with optical access have to be per-
formed in order to clarify to what degree this is true.
7
By reducing the value from 10 (which was used in Figure
13) to 3 in steps of 1, 8 different HRR curves were cre-
ated. All data in Table 2, except a for the diffusive com-
bustion, were kept constant. The different HRR curves
are shown in Figure 14. As can be seen, the premixed
portion of the heat release is not affected by the paramet-
ric change. This could of course be questioned since the
different HRR curves could be accomplished with fuel
rate shaping as will be discussed below. Thus the fuel
rate during the ignition delay could also be shaped and
the premixed portion would be more related to the fuel
rate during the diffusive phase. However, since this para-
metric study is chosen to demonstrate the general
approach it is of pedagogic value to simplify the paramet-
ric change.
PARAMETRIC STUDY
Figure 15. Pressure curves calculated with the HRR
In order to study the effect on NO, IMEP, ITE of different
curves shown in the Figure 14 above.
heat release rates and to calculate the corresponding
fuel rates, a set of calculations was performed where dif-
The pressure curves corresponding to the HRR shown in
ferent HRR were generated by changing the constant in
Figure 14 can be seen in the figure above. The maximum
equation (15) for the diffusive case. a
pressure is reduced from about 180 bar to 130 bar. The
location of the peak pressure is also changed.
8
For this reason it can be expected that the chosen heat
release rates will have a considerable influence on NO
formation, IMEP and ITE.
Figure 16 shows the relative NO versus the constant a in
the Vibe expression for the diffusive combustions. By rel-
ative is meant the normalized value expressed as per
cent. The calculated NO emission is almost halved over
the parameter range. This is mainly due to the reduction
of the maximum temperature.
9
By combining the results shown in Figures 16 and 18, the consumption, by improving the conditions for fast com-
trade-off between NO and ITE can be illustrated. This is bustion and injecting the fuel slowly and evenly.
done in Figure 20 above. As can be seen, the loss of effi-
ciency when NO is reduced by 45% is about 4.5%. The SUMMARY
corresponding value for a reduction of 20% is about 1%.
The presented parametric study is chosen to illustrate the This paper is focused on a simple approach to studying
approach. No attempts have been made to find the opti- the relation between fuel rate, heat release rate and NO
mum HRR in order to minimize NO with the least loss of formation in diesel engines. Models are presented for:
ITE. 1. Fuel flow calculations
2. The connection between fuel flow and heat release
rate
3. Creation of heat release rates with Vibe functions
4. NO calculations based on heat release rates [3]
In order to illustrate the approach, the different sub- mod-
els are connected and used in a parametric study where
the shape of the diffusive heat release rate is changed.
The effect of these changes on NO, indicated thermal
efficiency, indicated mean effective pressure and fuel rate
are presented.
CONCLUSION
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REFERENCES
CONTACT
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