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Shah, Bansal
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A Comprehensive CFD-FEA Conjugate Heat Transfer Analysis for Diesel and Gasoline Engines

Southwest Research Institute-Bansal Shah, Ahmed Moiz, Matthew Hoffmeyer, Zainal Abidin, Anthony Megel, Kevin Hoag
Published 2019-04-02 by SAE International in United States
As the efforts to push capabilities of current engine hardware to their durability limits increases, more accurate and reliable analysis is necessary to ensure that designs are robust. This paper evaluates a method of Conjugate Heat Transfer (CHT) analysis for a gasoline and a diesel engine that combines combustion Computational Fluid Dynamics (CFD), engine Finite Element Analysis (FEA), and cooling jacket CFD with the goal of obtaining more accurate temperature distribution and heat loss predictions in an engine compared to standard de-coupled CFD and FEA analysis methods. This novel CHT technique was successfully applied to a 2.5 liter GM LHU gasoline engine at 3000 rpm and a 15.0 liter Cummins ISX heavy duty diesel engine operating at 1250 rpm. Combustion CFD simulations results for the gasoline and diesel engines are validated with the experimental data for cylinder pressure and heat release rate. Radiation models were implemented to estimate heat transfer more accurately for diesel engine. FEA simulations are performed in a separate software platform. Data exchanges between CFD and FEA software codes are performed at…
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Evaluation of Diesel Spray with Non-Circular Nozzle - Part I: Inert Spray

Southwest Research Institute-Khanh Cung, Ahmed Abdul Moiz, Bansal Shah, Vickey Kalaskar, Jason Miwa, Zainal Abidin
Published 2019-01-15 by SAE International in United States
Numerous studies have characterized the impact of high injection pressure and small nozzle holes on spray quality and the subsequent impact on combustion. Higher injection pressure or smaller nozzle diameter usually reduce soot emissions owing to better atomization quality and fuel-air mixing enhancement. The influence of nozzle geometry on spray and combustion of diesel continues to be a topic of great research interest. An alternate approach impacting spray quality is investigated in this paper, specifically the impact of non-circular nozzles. The concept was explored experimentally in an optically accessible constant-volume combustion chamber (CVCC). Non-reacting spray evaluations were conducted at various ambient densities (14.8, 22.8, 30 kg/m3) under inert gas of Nitrogen (N2) while injection pressure was kept at 100 MPa. Shadowgraph imaging was used to obtain macroscopic spray characteristics such as spray structure, spray penetration, and the spray cone angle. Analysis from image processing showed expected result of lower penetration rate and higher spray cone angle as ambient density increased. Two slot nozzles with different aspect ratios but similar flow area as compared with one…
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Advances Toward the Goal of a Genuinely Conjugate Engine Heat Transfer Analysis

Southwest Research Institute-Matthew Hoffmeyer, Ahmed Abdul Moiz, Kevin Hoag, Anthony Megel, Bansal Shah, Zainal Abidin
Published 2019-01-15 by SAE International in United States
As the design of engines advances and continues to push the capabilities of current hardware closer to their durability limits, more accurate and reliable analysis is necessary to ensure that designs are robust. This research evaluates a method of conjugate heat transfer analysis for a diesel engine that combines the combustion CFD, Engine FEA, and cooling jacket CFD with the aim of getting more accurate heat loss predictions and a more accurate temperature distribution in the engine than with current analysis methods. A 15.0 L Cummins ISX heavy duty engine operating at 1250 RPM and 15 bar BMEP load is selected for this work. Spray combustion computational fluid dynamics (CFD) simulations are performed for the diesel engine and the results are validated with experimental data. Finite Element Analysis (FEA) simulations were performed in a separate software platform. Data interchanges between CFD and FEA software codes were performed at specified sub-cycle engine intervals and the simulations ran for multiple engine cycles. A comprehensive CFD-FEA conjugate heat transfer (CHT) methodology is proposed and the accuracy of this…
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Effect of Micro-Hole Nozzle on Diesel Spray and Combustion

Southwest Research Institute-Khanh Cung, Daniel Christopher Bitsis, Thomas Briggs, Vickey Kalaskar, Zainal Abidin, Bansal Shah, Jason Miwa
Published 2018-04-03 by SAE International in United States
The influence of nozzle geometry on spray and combustion of diesel continues to be a topic of great research interest. One area of promise, injector nozzles with micro-holes (i.e. down to 30 μm), still need further investigation. Reduction of nozzle orifice diameter and increased fuel injection pressure typically promotes air entrainment near-nozzle during start of injection. This leads to better premixing and consequently leaner combustion, hence lowering the formation of soot. Advances in numerical simulation have made it possible to study the effect of different nozzle diameters on the spray and combustion in great detail. In this study, a baseline model was developed for investigating the spray and combustion of diesel fuel at the Spray A condition (nozzle diameter of 90 μm) from the Engine Combustion Network (ECN) community. Upon validation of parameters such as spray penetration, lift-off length, and ignition delay the baseline simulation was extended to study different nozzle orifice diameters. All simulations were performed using a constant-volume combustion chamber (CVCC) geometry with similar ambient conditions of pressure (60 bar) and temperature (900 K). It was shown…
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