Nozzle Flow and Cavitation Modeling with Coupled 1D-3D AVL Software Tools

The paper is devoted to the coupled 1D-3D modeling technology of injector flow and cavitation in diesel injections systems. The technology is based on the 1D simulation of the injector with the AVL software BOOST-HYDSIM and 3D modeling of the nozzle flow with AVL FIRE. The nozzle mesh with spray holes and certain part of the nozzle chamber is created with the FIRE preprocessor. The border between the 1D and 3D simulation regions can be chosen inside the nozzle chamber at any position along the needle shaft. Actual coupling version of both software tools considers only one-dimensional (longitudinal) needle motion. Forthcoming version already includes the two-dimensional motion of the needle. Furthermore, special models for the needle tip contact with the nozzle seat and needle guide contact with the nozzle wall are developed in HYDSIM. The co-simulation technology is applied for different common rail injectors in several projects. It proved to be an efficient and user-friendly engineering tool. An example of piezoelectric common rail injector with a minisac nozzle is presented. Based on it, different numerical and technical aspects of the nozzle flow and cavitation modeling are discussed.