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In this study, different designs of intake ports for two-stroke Ultra Low Cost Gasoline Direct Injection Engine (ULC-GE) has been analyzed to conclude on best design using steady state analysis in STAR-CD. The four types of intake ports design with two cylinders, each having fourteen ports, have been studied. The basic differences in designs are horizontal inlet entry (perpendicular to cylinder axis) and vertical inlet entry (in-line with cylinder axis) having rotation of flow clockwise and anticlockwise. Each type is further differentiated in eight cases with varying distances between axis of two-cylinder as 85mm, 88mm, 91 mm, 94 mm, 97 mm, 100 mm, 105 mm and 112 mm. These designs are analyzed for four different pressure drops as 10 mbar, 50 mbar, 100 mbar and 150 mbar.

The main objective of this study is to determine the appropriate boundary conditions for the distribution of droplet sizes, speed of the fuel settling at the nozzle of the injector and droplet penetration by numerical simulation using STARCD for a 3-holes injector of ULC-GE. In this study, the Eulerian- Lagrangian approach has been used to model the multiphase domain. A new strategy has been adapted to model droplet initial conditions using the Rosin-Rammler distribution, which is determined by measurement of the Sauter Mean Diameter D₃₂ and the De Brouckere Mean Diameter D₄₃ by the MALVERN method. Further, these droplets undergo the phenomenon of atomization by secondary break-up method and evaporation in the Eulerian domain. The numerical model has been used to evaluate the effects of different initial condition of droplets by changing the discharge coefficient of the nozzle, and the initial droplet size distribution at the nozzle tip.