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Three high pressure multi-hole GDI injectors, one manufactured by Continental, two manufactured by Bosch, are experimentally characterized under various injection strategies in terms of instantaneous mass flow rate and fuel dispersion. Spray visualization within an optically accessible pressure vessel allows the measurement of the single jet cone angle and penetration length. A portable numerical model for the issuing spray dynamics is developed within the AVL Fire code, exploiting a log-normal distribution for the initial droplets diameter, whose expected value and variance are properly defined as a function of the main physical parameters. Tuning of the entering constants is realized by means of an automatic optimization procedure. An example of application of the spray model within a 3D simulation of the in-cylinder process of a GDI engine is presented. Effects of splitting injection into two successive events are discussed.

The paper aims at performing an environmental and energetic optimization of a naturally aspirated, light-duty direct injection (DI) diesel engine, equipped with a Common Rail injection system. Injection modulation into up to three pulses is considered starting from an experimental campaign conducted under non-evaporative conditions in a quiescent optically-accessible cylindrical vessel containing nitrogen at different densities. The engine performances in terms of power and emitted NOx and soot are reproduced by multidimensional modelling of the in-cylinder processes. The radiated noise is evaluated by resorting to a recently developed methodology, based on the decomposition of the CFD 3D computed in-cylinder pressure signal. Once validated, both the CFD and the acoustic procedures are applied to the simulation of the prototype engine and are coupled to an external optimizer with the aim of minimizing fuel consumption, pollutant emissions and radiated noise.

Vehicle exhaust emission control systems are most often operated under transient conditions as inlet gas species concentrations, temperature and mass flow rate vary in accordance with the driving conditions. The main objective of this article is to study the ignition and extinction phenomena associated with the reactions that occur in three way catalysts (TWC), in particular to evaluate the dependence of the ignition and extinction of the TWC reactions on the precious metal loading (PML). To this end, we report here transient experimental data for two ceramic TWC with different PML, one referred to as TWC-L (low PML) and the other as TWC-H (high PML). The present measurements were carried out on a vehicle equipped with a 2.8 liter V6 spark ignition engine that has multipoint fuel injection. During the experiments, different TWC were in turn placed in the so called under-floor position (about 1 m away from the engine) replacing the original TWC installed on the vehicle.

The work relates to the use of multidimensional modelling as a tool for improving the robustness of combustion of a Gasoline Direct Injection (GDI) Spark Ignition (SI) engine. A procedure is assessed for the prediction of the thermo-fluid-dynamic processes occurring in a single-cylinder, four-stroke engine, characterised by a bore-to-stroke ratio close to the unity, and a pent-roof head with four valves. The engine is at a design stage, under development for application on two wheels vehicles. A new generation six-holes Bosch injector is considered as realising a jet guided combustion mode. This last is preferred for its potential in realising effective charge stratification and great combustion stability under various operating conditions. The three-dimensional (3D) numerical model is developed within the AVL FIRE™ software environment.

Results of an experimental campaign conducted on a multi-hole gasoline injector are used to assess a numerical model for the spray dynamics suitable to be employed for the prediction of a GDI engine pressure cycle. The considered injector generates a spray with a hollow-ellipsoid footprint structure on a plane perpendicular to the spray axis. Spray penetration lengths and cone angles are measured at different injection pressures and total injected masses in an optically accessible vessel containing nitrogen at controlled conditions of temperature and pressure. Injected mass flow rate is measured on a Bosch tube. The numerical simulation is performed within the AVL Fire™ code environment. As a first step, the gasoline is considered as entering a constant volume environment containing nitrogen, in order to reproduce the effected experiments. Measured injection flow rates and cone angles are used as input variables for the model.

This paper deals with a CFD three-dimensional multiphase simulation of rotary vane pump. The paper presents a suitable methodology for the investigation of the cavitation effects and/or incondensable gases. All the 3D simulations were performed by using Fluent v12 (Beta version). A moving mesh methodology was defined to reproduce the change-in-time shape of the internal pump volumes. In particular, the pump analysis was focused on the generation, and evolution of the cavitation phenomena inside the machine to identify the locations where this phenomena could occur. Moreover, the influence of incondensable gas dissolved inside the operator fluid on both pump performance and cavitation evolution was evaluated. Significant results were obtained about the analysis of incondensable gas influence on the cavitation evolution showing that, today, CFD analysis can provide detailed information on such harmful phenomena which can not be achieved by experiments.

The main driving forces concerning the use of pre-primed automotive sheet are corrosion protection increase and cost reduction during vehicle manufacturing. In this work, the behaviour of two conductive primers, codified by 1 and 2, was studied and compared with that of a conventional electrophoretic primer. Primer 1 is an organic zinc rich silicate with a low thickness (near 4 μm) and primer 2 is a very thin (near 2 μm) solvent based primer filled with graphite. These primers were applied on electrogalvanized, hot dip galvanized and galvannealed steel sheets. Formability capabilities of pre-primed galvanized steel sheets were evaluated, through cupping and stone chipping tests, according to EN ISO 1520 and ASTM D3170, respectively. To evaluate corrosion protection, the samples were submitted to a corrosion cyclic test according to VDA procedure 621-415 contained in the SEP 1160.

A customised version of FIRE™ code is chosen to simulate the spray injected into a controlled environment by means of a Common Rail system driven via a Programmable Electronic Control Unit. Numerical results are compared to experimental data collected under various operating conditions, namely varying the injection pressure up to 120 MPa, and the gas back-pressure between 0.1 and 5.0 MPa. Non-evaporating conditions are considered. The employed optically accessible test chamber allows to light the spray with a flash lamp or a pulsed laser sheet, generated on the second harmonic of a Nd-YAG laser (532 nm, 12 ns in duration). Images are collected at different instants of time after the start of injection by means of a CCD camera. A digital image processing software is used to evaluate the major characteristics of the spray, as the penetration length and the cone angle. The injection flow rate is properly measured on a rate-of-injection flow bench for different injection strategies.

Multidimensional simulation of the soot formation process in a diesel engine is realised exploiting quantitative measurements of the soot volume fraction and diameter obtained by optical techniques. Broadband extinction and scattering measurements are performed on an optically accessible 4-stroke engine where a forced air motion allows a strong prevalence of the premixed stage of combustion with respect to the non-premixed one. Two semi-empirical models for soot formation are tested in the numerical simulation, which is performed using a customized version of the KIVA-3 code. The need of furnishing coherent values of the soot particles density and mean diameter to the one of the two models requiring this kind of information, is highlighted and demonstrated to be crucial in avoiding over-prediction of the soot concentration.

Quantitative measurements of the soot volume fraction and diameter performed by spectroscopic techniques within the combustion chamber of a diesel engine are employed to aid multidimensional simulation of the soot formation and oxidation processes. By changing the start of fuel injection, two different operating conditions are considered, which are characterized by different relative importance of the premixed to the diffusive stage of the combustion process. Both the reduced models by Hiroyasu et al., and the one by Nagle and Strikland- Constable are employed within the numerical simulation. The reason of the peculiar over-prediction of soot concentration of the latter model is discussed and related to the need of furnishing coherent values of the soot particle density and mean diameter.

The aim of this paper is to analyse the main concerns related to on board hydrogen catalytic production of fuel cell electric vehicles, starting from different gaseous and liquid fuels. In particular, limits and potentialities of hydrocarbons and alcohols have been examined, considering steam reforming and partial oxidation reactions with reference to emission and efficiency implications. Preliminary results of an experimental investigation on steam reforming of natural gas and liquid hydrocarbons are reported. Furthermore, a mono-dimensional mathematical model of methane steam reformer based on first order kinetics has been developed to simulate the experimental results.

Ignition delay in diesel engine combustion comprehends both a chemical and a physical amount, the first depending on fuel composition and charge temperature and pressure, the last resulting of time needed for the fuel to atomize, vaporize and mix with air. Control of this parameter, which is mandatory to weight the relative amount of premixed to diffusive stage of the hydrocarbon combustion, is here considered. Experimental measurements of flame intensity spectra obtained by in situ measurements on an optically accessible test device show the presence of peaks corresponding to radicals as OH and CH appearing at the pressure start of combustion. Since OH radicals result from chain branching reactions, a numerical simulation is performed based on a reduced kinetic scheme which allows to measure the branching agent concentration, and whose approximate nature is adequate to the proportion chemical aspects contribute to the overall delay.