In-Cylinder Engine Calculations: New Features and Upcoming Capabilities Richard Johns & Gerald Schmidt
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1 In-Cylinder Engine Calculations: New Features and Upcoming Capabilities Richard Johns & Gerald Schmidt
2 Contents Brief Review of STAR-CD/es-ice v4.20 Combustion Models Spray Models LES New Physics Developments in v4.22 Combustion Models PVM-MF Crank-angle resolved Conjugate Heat Transfer New Meshing Technologies Morphing/remeshing/mapping Overset Mesh
3 Combustion Models Combustion Models ECFM-3Z - Multi-fuel capability ECFM-CLEH - further development of emissions models - NORA NOx model, CO, soot PVM-MF - First Release Open Format for Fuel Libraries User chemistry mechanism Why do we have 3 combustion models? ECFM-CLEH will become the successor to ECFM-3Z PVM-MF combines the G-equation and flamelet concepts
4 Spray Models Wall Impingement Spray Models - Senda Droplet-Wall Interaction Model Developed by Prof. Senda at Doshisha University, Japan Covers three boiling heat transfer regimes with distinct submodels and extensive validation 2.1 ms 2.5 ms 2.9 ms Liquid Phase Vapor Phase Temperature = 398 K, Pressure = 0.5 MPa
5 LES LES Collaboration with University of Modena Focus on real-engine application: Cycle-by-cycle variations COV prediction Ignition process AKTIM and ISSIM models Knock sensitivity critical for highly rated and downsized engines Effect of non-uniform wall temperature CHT solution
6 GRUppoMOtori Internal Combustion Engine Research LES multicycle flame development 1 st 2 nd 3 rd 4 th 5 th 6 th 7 th 8 th 9 th 10 th 11 th 12 th 13 th 14 th 15 th 16 th 17 th 18 th 19 th 20 th
7 LES - 3D Results Insight: GRUppoMOtori Internal Combustion Engine Research Local flow field influence: 4 th fastest 16 th slowest A B A B A B A B
8 LES Correlation Coefficient 1 Correlation Coefficient (FSD_transition, Yj) ( X, Y i j ) abs( cov( X, Y ) var( X ) var( Y j j ) ) FSD_transition VS Yj (20 cycles) ER_local VMAG_local TE_local CCV itself relevantly depends on the FSD_transition CCV. This parameter (thus the transition between the ignition model and the FSD equation) is mostly influenced by equivalence ratio and velocity fields close to the spark plug at the spark time occurrence. GRUppoMOtori Internal Combustion Engine Research
9 Mapped Wall Temperature Conjugate Heat Transfer (CHT) analyses in Star-CCM+ to calculate the local heat transfer A realistic point-wise wall thermal field is applied to LES knocking combustion Mapped Wall Temperatures Combustion Dome Piston Crown GRUppoMOtori Internal Combustion Engine Research
10 [W] GRUppoMOtori Internal Combustion Engine Research Effect of Mapped Wall on Knock A more accurate prediction of knock is obtained Knock onset and intensity prediction benefit from the point-wise thermal field SAE Paper E+07 Heat Release Rate - Autoignition 1.E+06 1.E+05 1.E+04 1.E+03 1.E+02 1.E+01 1.E Crank Angle Uniform Wall - Fast Cycle Uniform Wall - Medium Cycle Uniform Wall - Slow Cycle Mapped Wall - Fast Cycle Mapped Wall - Medium Cycle Mapped Wall - Slow Cycle
11 Combustion PVM-MF The PVM-MF model has been enhanced particularly for dualfuel combustion An example is shown here of diesel/gas combustion based on the Westport combustion system Picture source:
12 PVM-MF Dual-Fuel Combustion Engine Details Bore 130 Stroke 150 Conrod 260 Compression ratio 18 Operating Condition Engine speed 1500 rev/min AFR-NG 30.3, AFR-Diesel 273 EGR 2.5% Fuel injection SOI Diesel 707 o CA, Duration 3 o SOI Gas 711 o CA, duration 16 o
13 Pressure (Pa) Temperature (K) PVM-MF Dual-Fuel Combustion Cylinder pressure and temperature 2.0E E E E E E E E E E+06 Pressure Temperature 1,800 1,600 1,400 1,200 1, E Crankangle (deg) 0
14 Heat release rate (J/sec) PVM-MF Dual-Fuel Combustion Heat release rate Diesel Natural gas 2.0E E E E E E E E E E E Crankangle (deg)
15 PVM-MF Dual-Fuel Combustion NG Diesel PV T 712o CA 710o CA 708o CA 711.5o CA
16 PVM-MF Dual-Fuel Combustion NG Diesel PV T 720o CA 715o CA 713o CA 717o CA
17 PVM-MF Dual-Fuel Combustion Fuel-1: Diesel Fuel-2: Natural gas
18 PVM-MF Dual-Fuel Combustion Combustion progress variable Temperature
19 Emissions models available in PVM-MF: Thermal Nitric Oxide Extended Zeldovich Mechanism (Daulch et al. 1973, Flower et al.1975, Monat et al. 1979) NO mass fraction (used in example) Flamelet Library (Lartsson et al. 1998) NO mass fraction Soot PVM-MF Dual-Fuel Combustion Das-Houtz-Reitz (1999) model implemented within ECFM-3Z Soot Mass (used in example) Moment Method (Lartsson et al. 1998) Soot Number Density Soot Volume Fraction Soot Surface Density Soot Mean Diameter Carbon Monoxide CO (Hautman et al. 1981) CO-CO2 Kinetics Chemistry implemented within ECFM-3Z CO mass fraction(used in example)
20 Temperature (K) Emissions mass fraction PVM-MF Dual-Fuel Combustion Emissions 1,700 1,600 1,500 1,400 1,300 Temperature Nox * 10 Soot CO 9.00E E E E E-03 1, E-03 1, E-03 1, E E E Crankangle (deg)
21 Crank-angle resolved Conjugate Heat Transfer Purpose of the Model: To have an easy-to-use capability for crank-angle resolved changes in surface temperature. Important for: Spray impingement reduced surface temperature and hence fuel evaporation rate which affects mixture distribution Surface coatings of high thermal resistance Easy-to-use by specifying a few simple parameters about the near-surface conducting layer 1D heat flow assumption does not need an additional mesh
22 Temperature Increase [K] Crank-angle resolved Conjugate Heat Transfer Temperature Increment vs Time Time = 1 ms 30 Time = 5 ms 25 Time = 10 ms Distance from surface [mm] Fluid Cell F Q F FSI Solid Layer SSI 4 Solid Layer contact resistance 7 8 B
23 Spray-induced heat transfer Cylindrical chamber, stationary mesh 20 mg of liquid C 8 H 18 sprayed toward the bottom wall 3 runs to validate the 1D CHT model T wall = 350 K 20 mg of C 8 H 18 T fuel = 293 K Duration = 5 ms Nozzle size = 0.2 mm BASELINE: bottom wall at a fixed temperature of 450 K CHT: 5 mm aluminum slab at bottom wall for 3D conjugate heat transfer calculation T air = 350 K P air = 1 bar T wall = 350 K 1DCHT: BASELINE mesh with 1D CHT model activated at bottom wall 3 runs to examine the effect of material property on wall temperature change T wall = 450 K (BASELINE) Conduction (CHT) T bulk = 450 K (1DCHT) 1.0k: standard aluminum property 0.5k: conductivity reduced by 50% 0.1k: conductivity reduced by 90%
24 Minimum Wall Temperature [K] Minimum Wall Temperature [K] Spray-induced heat transfer Predicted wall temperature at 15 ms after SOI BASELINE CHT 1DCHT Wall temperature distribution at 15 ms after SOI: No major differences between the CHT & 1DCHT predictions BASELINE CHT 1DCHT Time [ms] Minimum temperature on bottom wall as a function of time: No major differences between the CHT & 1DCHT predictions, justifying the use of the 1D CHT model _80_1.0k 2.50_80_0.5k 2.50_80_0.1k Time [ms] Thermal properties of the solid has a substantial effect on wall temperature, with low-conductivity material experiencing the largest temperature drop
25 Combustion induced heat transfer Cylindrical chamber, stationary mesh Premixed air & C 8 H 18, ignition at chamber center 3 runs to validate the 1D CHT model with 1.25mm BaTiO 3 (barium titanate) layer BASELINE: bottom wall at a fixed temperature of 500 K 1DCHT: BASELINE mesh with 1D CHT model activated at bottom wall CHT: slab at bottom wall for 3D conjugate heat transfer calculation 2 runs to examine the effect of material property on wall temperature change BaTiO 3 (1.25 mm) Aluminum (5 mm) T air = 800 K P air = 5 bar Ω = 2000 rpm Y C8H18 = T wall = 500 K T wall = 500 K (BASELINE) Conduction (CHT) T bulk = 500 K (1DCHT) t = 2.5 ms t = 5.0 ms t = 15.0 ms BaTiO 3 T wall = 500 K Aluminum Density [kg/m 3 ] Thermal conductivity [W/mK] Heat capacity [J/kgK] Thickness [mm]
26 Max. Wall Temperature [K] Max. Wall Temperature [K] Combustion induced heat transfer Predicted wall temperature 25 ms after SOI BASELINE CHT 1DCHT Maximum Wall Temperature vs Time BASELINE CHT_1.25mm 1DCHT_1.25mm Time [ms] 1DCHT_BaTiO3_1.25mm 1DCHT_Al_5.00mm Time [ms] Wall temperature distribution 25 ms after SOI: No major differences between the CHT & 1DCHT predictions Maximum wall temperature increase as a function of time: No major differences between the CHT & 1DCHT predictions; verifying the validity of the 1D CHT model Thermal properties of the solid has a strong effect on wall temperature increase, must be properly accounted for in order to achieve accurate combustion and emissions predictions
27 Summary of 1D CHT Model Multiple solid layers with contact resistance at solid-solid interfaces 1D energy balance on each solid cell Boundary conditions: Given heat flux (Q F ) from the fluid side (computed inside STAR-CD) Specified bulk temperature (T B ) at the solid side (specified by user) Resulting equations give a tri-diagonal system which is solved very efficiently Works with all existing STAR-CD models: Liquid Film Spray Combustion Boiling etc. Available early 2014
28 Overset mesh STAR-CCM+ technology Meshing for IC Engines Meshing technology is critical to the ease-of-use and accuracy of in-cylinder calculations In addition to the existing es-ice meshing methodology new methods have been developed for use with IC Engine flows The options that will become available are: More automation of the existing es-ice meshing Technology based on morphing/remeshing/mapping available in 2014
29 Morphing/Remeshing/Mapping - Setup Period: TDC > 30 o ABDC (210 o ) Period: TDC > 30 o ABDC (210 o ) Total of 6 meshes Scalar Flow & Mixing Max cells ~ 1.5M at BDC Solution mapped to next mesh Mesh morphed in - time Mesh morphed in + time Mesh generated at this time
30 Meshing Options Different types of meshes may be used at different stages of the calculation Constrained Polyhedra Prism Layers Core Cartesian Mesh Polyhedral Mesh Variable number of prism layers Local Coordinate Systems and Local Mesh Refinement
31 Example: 4-valve Gasoline Engine
32 Details around valve at low and high lifts
33
34 2-valve Gasoline with polyhedral mesh
35 2-valve Gasoline with polyhedral mesh
36 Inclusion of Spray-Adapted Mesh The same concept can be used to embed a local coordinate system for eg a spray-adapted mesh in a gasoline engine Selected morphing used to control mesh motion
37 Gasoline Spray-Adapted Mesh Period: TDC > 30 o ABDC (210 o ) Spray-adapted mesh between 80 o BBDC > 50 o BBDC Total of 7 meshes Max cells ~ 1.5M at BDC
38 Scalar Field from Intake Flow Gasoline Spray-Adapted Mesh
39 Overset Mesh
40 ICE in STAR-CCM+ CD-adapco is accelerating the development of full Internal Combustion Engine capabilities in STAR-CCM+ Development and Support of ICE in STAR-CD will continue indefinitely
41 Summary Significant Developments in all key areas: Combustion models multi-fuel, emissions developments Fuels open format for fuel chemistry libraries Sprays wall impingement models Crank-angle resolved conjugate heat transfer LES New automated and accurate meshing technologies Accelerated development of full ICE capability in STAR-CCM+
Combustion PVM-MF. The PVM-MF model has been enhanced particularly for dualfuel
Contents Extensive new capabilities available in STAR-CD/es-ice v4.20 Combustion Models see Marc Zellat presentation Spray Models LES New Physics Developments in v4.22 Combustion Models PVM-MF Crank-angle
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