Lib-ICE A C++ object-oriented library for internal combustion engine simulations: spray and combustion modeling

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1 5 th OpenFOAM Workshop, Goteborg, June 2010 Lib-ICE A C++ object-oriented library for internal combustion engine simulations: spray and combustion modeling T. Lucchini, G. D Errico, D. Ettorre, E. Spagnoli, G. Ferrari Internal Combustion Engine Group, Department of Energy Politecnico di Milano

2 Topics Development and application of numerical models (Lib-ICE) to simulate in-cylinder flows and combustion in IC engines using the OpenFOAM technology: Spray modeling Liquid film formation modeling Mesh management Diesel combustion SI-combustion Application to real engine cases, validation with experimental data.

3 Lib-ICE Code structure applications Diesel SI-Combustion Cold-flow Lib-ICE_1.5-dev OpenFOAM-dev Features of OpenFOAM+advaced models contributed by different research groups src utilities dieselspraypolimi thermophysicalmodelspolimi chemistrymodelpolimi wallfilmpolimi ldusolverspolimi

4 Mesh management Mesh management Automatic mesh motion, topological changes and adaptive local mesh refinement used in combination to ensure high grid quality and a reduced number of meshes to cover the simulation of the whole cycle. Work developed in collaboration with prof. H. Jasak and Dr. Zeljko Tukovic (University of Zagreb)

5 Lib-ICE spray models Review of the implemented capabilities Injection Atomization Breakup Evaporation Heat-transfer Wall impingement Collision Blob, Huh, Hollow-cone, Pressure-swirl Huh-Gosman, Bianchi, WAVE, LISA TAB, ETAB, KH-RT, Reitz-Diwakar Frossling Ranz-Marschall Naber-Reitz, Bai-Gosman, remove, rebound O Rourke, Nordin

6 Lib-ICE spray models Review of the implemented capabilities Injection Atomization Breakup Evaporation Heat-transfer Wall impingement Collision Blob, Huh, Hollow-cone, Pressure-swirl Huh-Gosman, Bianchi, WAVE, LISA TAB, ETAB, KH-RT, Reitz-Diwakar Frossling Ranz-Marschall Naber-Reitz, Bai-Gosman, remove, rebound O Rourke, Nordin

7 Spray models: new capabilities Blob injection: droplets are injected with the same nozzle diameter and injection velocity. Turbulent quantities (L t, τ t ) initialized for each droplet according to the nozzle flow conditions. Liquid jet atomization is modeled as: 1) Diameter reduction of the injected droplets 2) Stripping of secondary droplets from the liquid jet Model developed in collaboration with Prof. G. M Bianchi and Dr. F. Brusiani (DIEM - University of Bologna).

8 Spray models: new capabilities Diameter reduction of the injected parcels: dd dt = C 5 L a τ a Secondary droplet diameter at breakup-time: d stable = C w d prob R Multiphase LES calculations performed for different Reynolds nozzle number to: Identify suitable relations for L a and τ a Define the main model tuning constants (C w, C 5 ). Calculate the secondary droplet size at breakup time (d prob ) Sect. A Sect. B Sect. C

9 Spray models: new capabilities Model validation at constant-volume conditions 7-hole injector, opening angle: 148º. Nozzle diameter: mm Pilot+main injections considered for each operating point. Injected mass flow measured through the AVL flow rate meter. S1 S2 S3 S3 Strategy 1500 x x full 2500 x 8 Q pilot [mm 3 ] Q tot [mm 3 ] ρ AMB [kg/m 3 ] fuel inj. rate [mg/µs] x x x full Experimental data from Dr. Montanaro and Dr. Allocca (CNR-Istituto Motori, Naples) time [µs]

10 Spray models: new capabilities Application of Adaptive Local Mesh Refinement (ALMR) to a non-evaporating diesel spray case. 3 ms ASOI 6 ms ASOI Spray evolution correctly described in terms of: Primary and secondary breakup. Cone angle. Consistency and convergence of ALMR verified in previous works. 9 ms ASOI 12 ms ASOI

11 Spray models: new capabilities S1 S2 S3 S4

12 Wall film model: update Model implementation now completed. Solution of the liquid film governing equations: Mass Momentum Energy Improved calculation of the droplet impact pressure. Now the Bai-Gosman wall-impingement model is available. Support for parallelization and topological changes. Future developments: new impingement model to account for higher Weber impact numbers. Droplet formation model from sharp corners.

13 Wall film model: update Example of application: iso-octane droplets splashing on to a hot surface (400 K) Spray and liquid film temperature evolution. Fuel evaporation from liquid film. Work carried out in collaboration with Dr. Z. Tukovic and Prof. H. Jasak (FSB - University of Zagreb)

14 Lib-ICE: Diesel combustion Objective: Improve the existing combustion models to provide advanced diagnostic and development tools to design and simulate Diesel engines. Current models: TITC CTC PSR Tabulation of ignition delays + Eddy Dissipation model (4 species: fuel, air, products, egr) Shell Model + Characteristic Time-scale Combustion model (11 species, chemical equilibrium) Detailed chemistry + ISAT + DAC (TDAC)

15 Lib-ICE: Diesel combustion Objective: Improve the existing combustion models to provide advanced diagnostic and development tools to design and simulate Diesel engines. Current models: TITC CTC PSR Tabulation of ignition delays + Eddy Dissipation model (4 species: fuel, air, products, egr) Shell Model + Characteristic Time-scale Combustion model (11 species, chemical equilibrium) Detailed chemistry + ISAT + DAC (TDAC)

16 Diesel combustion CTC (Characteristic Time-scale Combustion Model) 11 chemical species (fuel, O 2, N 2, CO, CO 2, H 2 O, O, OH, NO, H, H 2 ) Auto-ignition computed by the Shell auto-ignition model (available set of constants for different fuels). Turbulent combustion simulated accounting for both laminar and turbulent time scales: Y i, TC = Y i Y τ C * i, where τ = τ + C l fτ t Incorporation of Zeldovich mechanism and Hiroyasu models to predict NO x and soot emissions. HC estimated as unburned fuel.

17 Diesel combustion: CTC model Experimental validation Common Rail Diesel Engine Work carried out in collaboration with Ing. Rita Di Gioia, Ing. Davide Carpentiero, Ing. Samuele Bertacchini (Magneti- Marelli Powertrain, Bologna). Spray-oriented grid to better predict the fuel-air mixing process Initial conditions at IVC (pressure, temperature) taken from 1D simulations of the whole engine system, including turbocharger and EGR Initial flow field: wheel-flow profile according to the experimental swirl ratio (2.2)

18 Diesel combustion: CTC model Experimental validation Common Rail Diesel Engine 1500 rpm, BMEP = 2 bar 100% 0% EGR Qpil Qpre Qmain Low load with high EGR rate and three injections

19 Diesel combustion: CTC model Experimental validation Common Rail Diesel Engine 1500 rpm, BMEP = 6 bar 100% 0% EGR Qpil Qpre Qmain Medium load with high EGR rate and three injections

20 Diesel combustion: CTC model Experimental validation Common Rail Diesel Engine 1500 rpm, BMEP = 12 bar 100% 0% EGR Qpil Qpre Qmain High load without EGR and three injections

21 Diesel combustion: CTC model Experimental validation Common Rail Diesel Engine 4000 rpm, BMEP = 16 bar 100% 0% EGR Qpil Qpre Qmain Full load without EGR and a single injection

22 Diesel combustion: CTC model Experimental validation Common Rail Diesel Engine Pollutant emissions NO x 1500 rpm NO x emissions NO x [ppm] Exp. Calc. BMEP [bar]

23 Diesel combustion: CTC model Experimental validation Common Rail Diesel Engine Pollutant emissions soot 1500 rpm soot emissions soot [ppm] Exp. Calc. BMEP [bar]

24 Diesel combustion - detailed chemistry (PSR) Detailed chemistry is necessary to describe the main features of the Diesel spray flame, both under conventional and new combustion modes: Auto-ignition Pollutant formation (soot, NO x ) Diffusion flame Proposed approach: perfectly stirred reactor (PSR) model based on direct integration of the chemical mechanism in each cell. ISAT+DAC (TDAC) technique applied to reduce the computational time. Work carried out in collaboration with Phd student Francesco Contino (University of Leouvain, Belgium). q ψ retrieve q ( ) l R ψ ISAT q ψ add grow q q R( ψ ) ( ) R ψ a DAC q ψ a ODE solver Speed-up factor: due to a reduction of ODE integrations.

25 Diesel combustion: PSR+TDAC Sandia optical engine: fuel-air mixing and combustion Calculations performed both at non-reacting and reacting conditions using a PRF29 fuel. Reduced chemical mechanism applied (49 species, 122 reactions). Two piston bowl configurations evaluated with different diameters and depths. Operating condition: partial load with 60% equivalent EGR. Compression simulated with a layered/coarse mesh, ALMR applied during fuel/air mixing and combustion. 70% bowl 80% bowl

26 Diesel combustion: PSR+TDAC Sandia optical engine: fuel-air mixing and flame propagation using ALMR and TDAC 4 CA 7 CA 14 CA 19 CA The grid is dynamically refined where the spray evolves and air-fuel mixing takes place. ALMR combined with TDAC: significant reduction of CPU time, but the accuracy is completely preserved.

27 Diesel combustion: PSR+TDAC 70% bowl, 8º ATDC 80% bowl, 9º ATDC 7 mm, exp 12 mm, exp 18 mm, exp 7 mm, exp 10 mm, exp 14 mm, exp 7 mm, calc 12 mm, calc 18 mm, calc 7 mm, calc 10 mm, calc 14 mm, calc Spray model validation: comparison with optical measurements of equivalence ratio distribution. Combustion model validation with in-cylinder pressure and heat release rate profiles.

28 Lib-ICE: SI-combustion ECFM-3z model now available in Lib-ICE. Possibility to simulate combustion in direct-injection, SI-engines accounting for: Ignition, modeled using the Eulerian AKTIM approach Turbulent combustion, using a 2- equation model transporting the flame surface density Σ flame propagation A u A b M u M b ρσ t + ρuiσ + x i = x ( P1 + P2 + P3 ) Σ D + Pk i µ Sc + µ t Sc t Σ x i F u unburned gases F b burned gases Mixing controlled combustion Burned gas composition computed at equilibrium. Possibility to predict soot, NO x and knock (Shell model).

29 SI-combustion Example of applications: flame kernel growth in an optical engine with central and peripheral ignition. Central ignition Peripheral ignition

30 Conclusions Lib-ICE combined with OpenFOAM-dev to simulate real IC engines: Gas exchange Fuel-air mixing including wall-film formation and evolution, Combustion (Diesel, SI, GDI, PCCI, HCCI) Future works: Identification of a suitable turbulence-chemistry interaction model for non-premixed combustion simulations with detailed chemistry. Including re-meshing techniques into the mesh-motion algorithms to further reduce the number of meshes and improve their quality. Introduction of detailed soot models for both Diesel and GDI combustion.

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