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Effects of a CFD-improved dimple stepped-lip piston on thermal efficiency and emissions in a medium-duty diesel engine
Diesel piston-bowl shape is a key design parameter that affects spray-wall interactions and turbulent flow development, and in turn affects the engine’s thermal efficiency and emissions. It is hypothesized that thermal efficiency can be improved by enhancing squish-region vortices as they are hypothesized to promote fuel-air mixing, leading to faster heat-release rates. However, the strength and longevity of these vortices decrease with advanced injection timings for typical stepped-lip (SL) piston geometries. Dimple stepped-lip (DSL) pistons enhance vortex formation at early injection timings. Previous engine experiments with such a bowl show 1.4% thermal efficiency gains over an SL piston. However, soot was increased dramatically [SAE 2022-01-0400]. In a previous study, a new DSL bowl was designed using non-combusting computational fluid dynamic simulations. This improved DSL bowl is predicted to promote stronger, more rotationally energetic vortices than the baseline DSL piston: it employs shallower, narrower, and steeper-curved dimples that are placed further out into the squish region. In the current experimental study, this improved bowl is tested in a medium-duty diesel engine and compared against the SL piston over an injection timing sweep at low-load and part-load operating conditions. No substantial thermal efficiency gains are achieved at the early injection timing with the improved DSL design, but soot emissions are lowered by 45% relative to the production SL piston, likely due to improved air utilization and soot oxidation. However, these benefits are lost at late injection timings, where the DSL piston renders a lower thermal efficiency than that of the SL piston. Energy balance analyses show higher wall heat transfer with the DSL piston than with the SL piston despite a 1.3% reduction in the piston surface area. Vortex enhancement may not necessarily lead to improved efficiency as more energetic squish-region vortices can lead to higher convective heat transfer losses.
Testing Ceramics for Diesel Engines
Adaptation of diesel engine allows prestressed ceramic materials evaluated under realistic pressure, temperature, and stress without introducing extraneous stress. Ceramic specimen part of prechamber of research engine. Specimen held in place by clamp, introduces required axial compressive stress. Specimen -- cylindrical shell -- surrounded by chamber vented or pressurized to introduce requisite radial stress in ceramic. Pressure chamber also serves as safety shield in case speimen disintegrates. Materials under consideration as cylinder liners for diesel engines.
The Fundamental Principles of High-speed Semi-diesel Engines. Part I: a General Discussion of the Subject of Fuel Injection in Diesel Engines and Detailed Descriptions of Many Types of Injection Nozzles
Three questions relating to the technical progress in the utilization of heavy oils are discussed. The first question considers solid injection in high-speed automobile engines, the second concerns the development of the hot-bulb engine, and the third question relates to the need for a more thorough investigation of the processes on which the formatation of combustible, rapidly-burning mixtures depend.
Ducted Fuel Injection and Cooled Spray Technologies for Particulate Control in Heavy-Duty Diesel Engines
Heavy-Duty diesel engine manufacturers are continuously in pursuit of simple and low-cost technologies that can reduce emissions. Ducted fuel injection (DFI) and Cooled Spray (CS) technologies are two technologies that continue to show promise for significant particulate emissions reductions. These technologies represent a breakthrough in diesel engine combustion from the potential of nearly sootless diesel combustion. This can provide a significant decrease in harmful PM emissions and may enable further system optimization for reduced NOx emissions and increased efficiency. Combustion vessel experiments and engine demonstrations at Sandia, together with the large bore engine tests performed by Wabtec show that this technology may be applicable to heavy duty diesel engines across a wide range of engine sizes and speeds representing the majority of off-road diesel engines. However, very little is known about the ideal geometry, scaling properties or effectiveness of these technologies over the engine operating map. This project will address those uncertainties through a series of experiments performed in an optical and a metal single-cylinder engine.
Ignition points and combustion reactions in Diesel engines. Part II
Ignition point measurement and ignition point test equipment is examined.
Lightweight, low compression aircraft diesel engine
The feasibility of converting a spark ignition aircraft engine to the diesel cycle was investigated. Procedures necessary for converting a single cylinder GTS10-520 are described as well as a single cylinder diesel engine test program. The modification of the engine for the hot port cooling concept is discussed. A digital computer graphics simulation of a twin engine aircraft incorporating the diesel engine and Hot Fort concept is presented showing some potential gains in aircraft performance. Sample results of the computer program used in the simulation are included.
Thermal barrier coatings application in diesel engines
Commercial use of thermal barrier coatings in diesel engines began in the mid 70's by Dr. Ingard Kvernes at the Central Institute for Industrial Research in Oslo, Norway. Dr. Kvernes attributed attack on diesel engine valves and piston crowns encountered in marine diesel engines in Norwegian ships as hot-corrosion attributed to a reduced quality of residual fuel. His solution was to coat these components to reduce metal temperature below the threshold of aggressive hot-corrosion and also provide protection. Roy Kamo introduced thermal barrier coatings in his 'Adiabatic Diesel Engine' in the late 70's. Kamo's concept was to eliminate the engine block water cooling system and reduce heat losses. Roy reported significant performance improvements in his thermally insulated engine at the SAE Congress in 1982. Kamo's work stimulates major programs with insulated engines, particularly in Europe. Most of the major diesel engine manufacturers conducted some level of test with insulated combustion chamber components. They initially ran into increased fuel consumption. The German engine consortium had Prof. Woschni of the Technical Institute in Munich. Woschni conducted testing with pistons with air gaps to provide the insulation effects. Woschni indicated the hot walls of the insulated engine created a major increase in heat transfer he refers to as 'convection vive.' Woschni's work was a major factor in the abrupt curtailment of insulated diesel engine work in continental Europe. Ricardo in the UK suggested that combustion should be reoptimized for the hot-wall effects of the insulated combustion chamber and showed under a narrow range of conditions fuel economy could be improved. The Department of Energy has supported thermal barrier coating development for diesel engine applications. In the Clean Diesel - 50 Percent Efficient (CD-50) engine for the year 2000, thermal barrier coatings will be used on piston crowns and possibly other components. The primary purpose of the thermal barrier coatings will be to reduce thermal fatigue as the engine peak cylinder pressure will nearly be doubled. As the coatings result in higher available energy in the exhaust gas, efficiency gains are achieved through use of this energy by turbochargers, turbocompounding or thermoelectric generators.
Ignition points and combustion reactions in Diesel engines. Part I
The question of whether the fuel should be adapted to the engine or whether it is possible to improve equipment such as carburetors and engines so that as much of the crude oil as possible may be used without further transformation is examined in this report. Various ignition points and fuel mixtures are investigated in this regard.
Vehicle testing of Cummins turbocompound diesel engine
Two turbocompound diesel engines were installed in Class VIII heavy-duty vehicles to determine the fuel consumption potential and performance characteristics. One turbocompound powered vehicle was evaluated at the Cummins Pilot Center where driveability, fuel consumption, torsional vibration, and noise were evaluated. Fuel consumption testing showed a 14.8% benefit for the turbocompound engine in comparison to a production NTC-400 used as a baseline. The turbocompound engine also achieved lower noise levels, improved driveability, improved gradeability, and marginally superior engine retardation. The second turbocompound engine was placed in commercial service and accumulated 50,000 miles on a cross-country route without malfunction. Tank mileage revealed a 15.92% improvement over a production NTCC-400 which was operating on the same route.
Thermal barrier coatings application in diesel engines
Commercial use of thermal barrier coatings in diesel engines began in the mid 70's by Dr,. Ingard Kvernes at the Central Institute for Industrial Research in Oslo, Norway. Dr. Kvernes attributed attack on diesel engine valves and piston crowns encountered in marine diesel engines in Norwegian ships as hot-corrosion attributed to a reduced quality of residual fuel. His solution was to coat these components to reduce metal temperature below the threshold of aggressive hot-corrosion and also to provide protection. The Department of Energy has supported thermal barrier coating development for diesel engine applications. In the Clean Diesel - 50 Percent Efficient (CD-50) engine for the year 2000, thermal barrier coatings will be used on piston crowns and possibly other components. The primary purpose of the thermal barrier coatings will be to reduce thermal fatigue as the engine peak cylinder pressure will nearly be doubled. As the coatings result in higher available energy in the exhaust gas, efficiency gains are achieved through use of this energy by turbochargers, turbocompounding or thermoelectric generators.
Ignition and combustion phenomena in Diesel engines
Evidences were found that neither gasification nor vaporization of the injected fuel occurs before ignition; also that the hydrogen coefficient has no significance. However the knowledge of the ignition point and of the "time lag" is important. After ignition, the combustion proceeds in a series of reactions, the last of which at least are now known.
Overview of thermal barrier coatings in diesel engines
An understanding of delamination mechanisms in thermal barrier coatings has been developed for diesel engine applications through rig tests, structural analysis modeling, nondestructive evaluation, and engine evaluation of various thermal barrier coatings. This knowledge has resulted in improved thermal barrier coatings which survive abusive cyclic fatigue tests in high output diesel engines. Although much conflicting literature now exists regarding the impact of thermal barrier coatings on engine performance and fuel consumption, the changes in fuel consumption appear to be less than a few percent and can be negative for state-of-the-art diesel engines. The ability of the thermal barrier coating to improve fuel economy tends to be dependent on a number of factors including the fuel injection system, combustion chamber design, and the initial engine fuel economy. Limited investigations on state-of-the-art diesel engines have indicated that the surface connected porosity and coating surface roughness may influence engine fuel economy. Current research efforts on thermal barrier coatings are primarily directed at reducing in-cylinder heat rejection, thermal fatigue protection of underlying metal surfaces and a possible reduction in diesel engine emissions. Significant efforts are still required to improve the plasma spray processing capability and the economics for complex geometry diesel engine components.
Conventional engine technology. Volume 2: Status of diesel engine technology
The engines of diesel cars marketed in the United States were examined. Prominent design features, performance characteristics, fuel economy and emissions data were compared. Specific problems, in particular those of NO and smoke emissions, the effects of increasing dieselization on diesel fuel price and availability, current R&D work and advanced diesel concepts are discussed. Diesel cars currently have a fuel economy advantage over gasoline engine powered cars. Diesel drawbacks (noise and odor) were reduced to a less objectionable level. An equivalent gasoline engine driveability was obtained with turbocharging. Diesel manufacturers see a growth in the diesel market for the next ten years. Uncertainties regarding future emission regulation may inhibit future diesel production investments. With spark ignition engine technology advancing in the direction of high compression ratios, the fuel economy advantages of the diesel car is expected to diminish. To return its fuel economy lead, the diesel's potential for future improvement must be used.
Documentation of the Benson Diesel Engine Simulation Program
This report documents the Benson Diesel Engine Simulation Program and explains how it can be used to predict the performance of diesel engines. The program was obtained from the Garrett Turbine Engine Company but has been extensively modified since. The program is a thermodynamic simulation of the diesel engine cycle which uses a single zone combustion model. It can be used to predict the effect of changes in engine design and operating parameters such as valve timing, speed and boost pressure. The most significan change made to this program is the addition of a more detailed heat transfer model to predict metal part temperatures. This report contains a description of the sub-models used in the Benson program, a description of the input parameters and sample program runs.
An indirect approach to optimize the reaction rates of thermal NO formation for diesel engines
With stringent emission regulations, it has become more important for modern diesel engine manufacturers to accurately predict engine-out nitrogen oxide (NO x ) emissions across a wide range of operating conditions. Thermal NO is the major source of engine-out NO x in modern diesel engines. For thermal NO formation, several earlier studies have recommended the forward and reverse reaction rate coefficients of the rate-limiting reaction (O + N 2 ⇌ NO + N). However, due to deficiencies in sub-models and inadequacies of reduced chemical mechanisms to represent diesel combustion, these recommended values more often than not need to be adjusted in reduced order combustion models to accurately predict engine-out NO x . Hence, in this work a systematic and computationally efficient approach has been proposed to streamline the process of determining the optimum reaction rate coefficients. Here, to develop the optimization approach, four different production diesel engines with different operating conditions in terms of speed, load, and exhaust-gas recirculation have been considered. Numerical simulations have been performed using a detailed zero-dimensional velocity-composition-frequency transported probability density function (0D-VCF-tPDF) model that uses hundreds of notional particles to capture in-cylinder stratification. Four different combinations of hydrocarbon and NO x chemical mechanisms were used to represent chemistry. It was found that for the rate-limiting reaction, the pre-exponent factors (A f1 , A r1 ) and activation energies (E A,f1 , E A,r1 ) of the forward and reverse reaction rates follow a linear band in A f1 - E A,f1 and A r1 - E A,r1 space where predicted engine-out NO x match the measured values closely. By encompassing such bands from different engines and considering constraints on activation energies, a reduced search domain of pre-exponent factors and activation energies was constructed that is expected to be applicable to any diesel engine. Eventually, computationally efficient three-line and one-line search approaches were proposed to determine the optimum values of the pre-exponent factors and activation energies that led to a minimum error between measured and predicted engine-out NO x . Finally, these three-line and one-line NO x optimization approaches were applied to a fifth production diesel engine for which the 0D-VCF-tPDF model showed a very good predictive performance in terms of predicting peak pressure, 50% burn rate, and engine-out NO x when compared to measured and 3D-CFD values.
Recent suggestions in Diesel-engine construction
Different methods for increasing the efficiency of diesel engines are presented and some new designs are given.