Università degli studi di Modena e Reggio Emilia

The paper reports a wide numerical analysis of the well-known "Darmstadt engine"operated under motored condition. The engine, which features multiple optical accesses and is representative of currently made four-valve pentroof GDI production engines, is simulated using computational grids of increasing density and two widely adopted approaches to model turbulence, Reynolds Averaged Navier Stokes (RANS) and Large Eddy Simulation (LES). In the first part of the paper, attention is focused on the increase of grid density within the RANS modelling framework: both bulk-flow grid density and near-wall grid density are varied in order to analyse potentials and limitations of the different grid strategies and evaluate the trade-off between accuracy and computational cost. In the second part of the paper, an analysis is made, on equal grid density, to compare RANS and LES modelling frameworks and to highlight the improved capability of the latter in representing the spatial and temporal evolution of the in-cylinder turbulent flow structures. Results from the CFD analyses are compared with detailed PIV measurements on different planes and at different crank angle positions; furthermore, quantitative comparisons are performed using well-established quality indices.

Computational fluid dynamics has become a fundamental tool for the design and development of internal combustion engines. The meshing strategy plays a central role in the computational efficiency, in the management of the moving components of the engine and in the accuracy of results. The overset mesh approach, usually referred to also as chimera grid or composite grid, was rarely applied to the simulation of internal combustion engines, mainly because of the difficulty in adapting the technique to the specific complexities of internal combustion engine flows. The article demonstrates the feasibility and the effectiveness of the overset mesh technique application to internal combustion engines, thanks to a purposely designed meshing approach. In particular, the technique is used to analyze the cycle-to-cycle variability of internal combustion engine flows using large eddy simulation. Fifty large eddy simulation cycles are performed on the well-known TCC-III engine in motored condition. Results are analyzed in terms of tumble center trajectory and using proper orthogonal decomposition to objectively characterize the spatial and temporal evolution of turbulent flow field in internal combustion engines. In particular, an original decomposition method previously applied by the authors to the TCC-III measured flow fields is here extended to computational fluid dynamics results.

In the present paper, 1D and 3D CFD models of the Darmstadt research engine undergo a preliminary validation against the available experimental dataset at motored condition. The Darmstadt engine is a single-cylinder optical research unit and the chosen operating point is characterized by a revving speed equal to 800 rpm with intake temperature and pressure of 24 °C and 0.95 bar, respectively. Experimental data are available from the TU Darmstadt engine research group. Several aspects of the engine are analyzed, such as crevice modeling, blow-by, heat transfer and compression ratio, with the aim to minimize numerical uncertainties. On the one hand, a GT-Power model of the engine is used to investigate the impact of blow-by and crevices modeling during compression and expansion strokes. Moreover, it provides boundary conditions for the following 3D CFD simulations. On the other hand, the latter, carried out in a RANS framework with both highand low-Reynolds wall treatments, allow a deeper investigation of the boundary layer phenomena and, thus, of the gas-to-wall heat transfer. A detailed modeling of the crevice, along with an ad hoc tuning of both blow-by and heat fluxes lead to a remarkable improvement of the results. However, in order to adequately match the experimental mean in-cylinder pressure, a slight modification of the compression ratio from the nominal value is accounted for, based on the uncertainty which usually characterizes such geometrical parameter. The present preliminary study aims at providing reliable numerical setups for 1D and 3D models to be adopted in future detailed investigations on the Darmstadt research engine.

The statistical tendency of a GDI spark-ignition engine to undergo knocking combustion as a consequence of spark timing variation is numerically investigated. In particular, attention is focused on the importance to match combustion-relevant and knock-relevant fuel properties to ensure consistency with the experimental evidence. An inhouse surrogate formulation methodology is used to emulate real gasoline properties, comparing fuel models of increasing complexity. Knock is investigated using a proprietary statistical knock model (GruMo Knock Model, GK-PDF). The model can infer a log-normal distribution of knock intensity within a RANS formalism, by means of transport equations for variances and turbulence-derived probability density functions (PDFs) for physical quantities. The calculated distributions are compared to measured statistical distributions. The proposed numerical/experimental comparison constitutes an advancement in synthetic chemistry integration into 3D-CFD combustion simulations.

The evaluation of Internal Combustion Engine (ICE) flows by 3D-CFD strongly depends on a combination of mutually interacting factors, among which grid resolution, closure model, numerics. A careful choice should be made in order to limit the extremely high computational cost and numerical problems arising from the combination of refined grids, high-order numeric schemes and complex geometries typical of ICEs. The paper focuses on the comparison between different grid strategies: in particular, attention is focused firstly on near-wall grid through the comparison between multi-layer and single-layer grids, and secondly on core grid density. The performance of each grid strategy is assessed in terms of accuracy and computational efficiency. A detailed comparison is presented against PIV flow measurements of the Spray Guided Darmstadt Engine available at the Darmstadt University of Technology. As many research groups are simultaneously working on the Darmstadt engine using different CFD codes and meshing approaches, it constitutes a perfect environment for both method validation and scientific cooperation. A motored engine condition is chosen and the flow evolution throughout the engine cycle is evaluated on two different section planes. Pros and cons of each grid strategy are highlighted and motivated.

The accurate representation of Internal Combustion Engine (ICE) flows via CFD is an extremely complex task: it strongly depends on a combination of highly impacting factors, such as grid resolution (both local and global), choice of the turbulence model, numeric schemes and mesh motion technique. A well-founded choice must be made in order to avoid excessive computational cost and numerical difficulties arising from the combination of fine computational grids, high-order numeric schemes and geometrical complexity typical of ICEs. The paper focuses on the comparison between different mesh motion technologies, namely layer addition and removal, morphing/remapping and overset grids. Different grid strategies for a chosen mesh motion technology are also discussed. The performance of each mesh technology and grid strategy is evaluated in terms of accuracy and computational efficiency (stability, scalability, robustness). In particular, a detailed comparison is presented against detailed PIV flow measurements of the well-known "TCC Engine III" (Transparent Combustion Chamber Engine III) available at the University of Michigan. Since many research groups are simultaneously working on the TCC engine using different CFD codes and meshing approaches, such engine constitutes a perfect playground for scientific cooperation between High-Level Institutions. A motored engine condition is chosen and the flow evolution throughout the engine cycle is evaluated on four different section planes. Pros and cons of each grid strategy as well as mesh motion technique are highlighted and motivated.

The present engine development pathway for increased specific power and efficiency is moving Spark-Ignition engines towards unprecedented levels of mean thermo-mechanical loading. This in turn promotes undesired abnormal combustion events in the unburnt mixture (also called “engine knock”), leading to solid parts failure and constituting a severe upper constraint to engine efficiency. In this context, CFD simulations are regularly used to investigate the fluid-dynamic reasons for engine knock and to address knock suppression strategies, using dedicated models to simulate the chemical reaction rate of the fuel/air/residual mixture at the same thermodynamics states as those encountered in engines. In this paper three different approaches are coherently compared to simulate knock occurrence on a turbocharged GDI engine, representing some of the most popular choices for modelers in the RANS framework. The first one considers the on-the-fly solution of chemical reactions, which represents the state-of-the-art knock modelling approach albeit its problematic computational cost for industrial turnaround times. The other two methods consider pre-calculated libraries of ignition delay times (calculated at constant pressure and volume, respectively) for the same fuel model, and knock timing is predicted using a classical Livengood-Wu approach coupled to the same main combustion model. All the analyzed models for the end-gas reaction rate are coupled with a dedicated combustion model for propagating flame (G-equation). A comprehensive analysis of computational cost and of knock prediction accuracy is carried out for library-based methods against the detailed chemistry model. Finally, results are critically discussed and explained using combined ignition delay time maps and traces for thermodynamic in-cylinder states, and guidelines for the a priori choice for constant pressure- or volume-generated libraries are provided. In this context, the use of a synthetic knock model combined with libraries of ignition delays calculated at constant volume emerges as an accurate and efficient modelling strategy. The study outlines a method for the well-supported use of simplified CPU-efficient models, with a promoted confidence in simulation results from the comparison with detailed chemistry.