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The success obtained by use of Virtual Engine Modeling (VEM) in the design and development areas of fuel injectors generated a lot of interest from production and quality engineers to dispose of a similar tool related to spray vessel measurements. To respond to stringent PL6/EURO5 requirements it was decided to develop a Virtual Spray Vessel (VSV) tool capable of predicting spray patters and perform droplet diameter analysis comparable to Phase Doppler Analysis (PDA) results. The paper describes the analogies between VEM and VSV modeling, the specific new numerical approaches to obtain spatial spray data comparable to conventional mechanical measurement techniques and to perform droplet diameter analysis comparable to PDA data. The paper concludes with a series of comparisons of simulated and experimental data.

The first part of the paper gives an overview of the results obtained with European GDI-powered vehicles launched on the market. Thereafter, a discussion of in-vehicle limitations due to the exhaust gas after-treatment system requirements is given. The paper continues with a description of the current development status of European lean stratified direct injection system layouts. A detailed presentation is made of the mixture preparation system key components, basic control algorithms and the necessary new high-level experimental and analytical development tools. Particularly the topic of the multi-purpose use of 3-D numerical simulation is addressed both in the development and the engine control strategy calibration phases. The development of a small 1.6 liter lean stratified engine project is taken as example to demonstrate the dual application capability of the 3D simulation tool.