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An important challenge for modeling Direct-Injection Spark-Ignition (DISI) gasoline engines is understanding flash boiling spray. Flash boiling occurs when the ambient pressure is lower than the vapor pressure of the fuel and affects the spray structure and mixture formation process inside an engine. Gasoline is a multi-component fuel and the effects of each component on flash boiling are difficult to estimate. As a preliminary study to investigate the mixture formation process of the flash boiling spray, a single-component fuel was used to validate the flash breakup model. The flash breakup model was applied to KIVA 3V release2. Bubble growth in the drop was modelled by the Rayleigh-Plesset equation. When bubbles grow to satisfy the breakup criterion, breakup occurs and induces a smaller SMD for flash breakup cases. To investigate flash breakup modeling, simulations without the flash breakup model and with the flash breakup model was compared.

Incorporating lean burn engine technology has been considered as one of the most promising methods for improving fuel economy and reducing emissions. There has been, however, difficulity in expanding the compatibility region, where both the extension of LML(Lean Misfire Limit) and the reduction of NOx are simultaneously achieved while keeping satisfactory drivability. The lean misfire limit has been extended by the introduction of swirl and tumble motion. Three types of ports with an IACV(Intake Air Control Valve) have been developed to satisfy seemingly contradictory requirements of obtaining sufficient swirl and tumble motion to improve combustion and still keep high volumetric efficiency. Effects of newly designed ports with IACV on LML, emissions(NOx, THC, CO), BSFC, MBT, were confirmed in a four cylinder engine. Tests showed that the combustion duration was shortened and consequently lean misfire limit and EGR tolerance were improved. Emission level of NOx is considerably reduced.

This paper describes the development process and test results of the lean burn engine. LML (Lean Misfire Limit) extension and NOx emission reduction was realized in combination with the following factors. (1) Installing several types of SCV (Swirl Control Valve) with different section shapes and dividing wall in the intake port intensified the flow field inside combustion chamber, so optimized mixture formation and combustion improvement were obtained. (2) By precisely controlling injection timing, changing injection rate, thus obtaining locally stratified charging, LML was extended. (3) By intensifying ignition system, better combustion characteristics were achieved. (4) NOx emission was reduced by extending LML and adopting lean NOx catalyst (Cu-ZSM-5). By combining above factors, we extended LML to A/F 23. Therefore NOx emission was reduced 60.6%, fuel economy was improved 10.6% in engine dyno test. BY ECU mapping test, we fixed lean operating zone.