Optimizing Diesel Engine Performance through Parametric Study of Fuel Injector Configurations for Enhanced Sustainability

The pursuit of sustainable transportation solutions requires continuous improvement in engine efficiency and performance. This study presents a comprehensive parametric analysis of high-horsepower diesel engine combustion modeling, focusing on fuel injector configurations to optimize power density and overall engine efficiency. The model was first validated with experimental data. Based on the validated model, a series of Design of Experiments (DoE) simulations were conducted, examining four distinct fuel injector hole configurations, each with four different spray inclusion angle (umbrella angle) variations. The set of different fuel injector configurations was selected through benchmarking analysis. The primary objective was to identify the most effective injector design for improved combustion characteristics and engine performance. Upon determining the superior configuration, further simulations were performed with increased injector throughflow to fine-tune the optimal design. Additionally, the piston bowl configurations were adjusted to achieve better combustion efficiency. The methodology involved advanced computational fluid dynamics (CFD) modeling techniques to simulate various injector configurations under diverse operating conditions. Performance metrics such as power rating, fuel-specific consumption, combustion efficiency, and emissions were meticulously analyzed to evaluate each configuration's impact on engine power density and overall efficiency. Results revealed noticeable variations in engine characteristics across different injector designs. The optimal configuration demonstrated superior fuel atomization and spray characteristics, enhancing combustion efficiency and reducing emissions, and the results were also correlated with the experimental findings. These findings provide valuable insights for the development of more sustainable and efficient high-horsepower diesel engines.