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A 3-D analysis of the flow through a multihole, V.C.O. (Valve Covered Orifice) nozzle for D.I. Diesel Engine has been carried out. The analysis was performed by means of a finite element code. The nozzle comprises five injection holes. Aims of the analysis were: the investigation of the pressure drops along the conical clearance between the needle and the nozzle; the evaluation of the energy losses in the injection holes; the disclosure of the velocity profile at the injection hole outlets. the differences of flowrate for each hole with geometrical asymmetries. This kind of analisys is the first step of a more complete spray analysis; in fact, the spray from an injection hole is influenced by the injection pressure and the velocity profile. In particular, the needle lift and the needle tip deviation have been parametrized. The analysis betters both the theoretical knowledge of this kind of nozzle and the hydraulic phenomena occurring inside.

A simulation model of an injection system for reciprocating engines has been developed to study the influence of the geometrical and mechanical configuration of the injection apparatus on the injection flow characteristics. The suggested model simulates pressure wave propagation in the pipelines, particularly in presence of cavitation, and injector behaviour. The model used for nozzle simulation evaluates fluid-dynamic phenomena in the nozzle sections and chambers. This allows prediction of injector geometry influence on the flow parameters and simulation of general behaviour of the apparatus and the spray using different nozzles (with sac, without sac, with reduced sac). Lastly, a model of the structure by a finite elements method allows the study of dynamics of the moving elements. The mathematical model has been verified through a series of experimental measurements. The comparison between numerical and experimental results has been satisfactory.

The present study focuses on the causes of dissimilarity in the flow structures of sprays produced by different holes of the same direct injection high-pressure diesel nozzle. To assess the effect of nozzle geometry on the transient spray structure, photographs of the spray plumes produced by VCO, mini-sac and reduced sac nozzles at different delays from the start of injection were acquired. Injected fuel volume, feeding pressure, injection duration, spray penetration and cone angle were measured for all the investigated nozzles. A statistical analysis of the acquired images and data showed that sprays from the same hole were highly repeatable even with clear hole-to-hole variation of the spray structure. In particular, for the three investigated nozzle geometries the effect of nozzle flow rate, hole inlet and outlet diameter, needle geometry and working time under engine conditions were investigated. Microscope pictures of the nozzle holes were also acquired.