Application of Computational Fluid Dynamics for Flow Force Optimization of a High Pressure Fuel Injector Spill Valve

Development of Caterpillar Fuel Systems' MEUI-B injector has involved application of Computational Fluid Dynamics (CFD) in order to improve performance of the high pressure spill valve. Initial performance bench testing with concept stage experimental injectors indicated that the chamber pressure was decaying at an unacceptably slow rate, and the valve demonstrated erratic behavior at some operating conditions. The slow pressure decay and inconsistent spill valve motion were believed to be caused by flow forces generated during the low lift portion of the spill valve opening event. This theory was pursued by utilizing CFD to design two valves for testing in the next phase of the injector development cycle: A baseline geometry, similar to the original concept injector valve, and a new design incorporating localized seat geometry changes for inducing flow force assisted valve opening. Bench test performance data clearly shows that the modified design significantly improves the spill valve opening event and subsequent chamber pressure decay rate. This paper documents the CFD analysis which led to the development of the new MEUI-B high pressure spill valve design.