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This paper describes a novel design and verification process for analytical methods used in the development of advanced combustion strategies in internal combustion engines (ICE). The objective was to improve brake thermal efficiency (BTE) as part of the US Department of Energy SuperTruck program. The tools and methods herein discussed consider spray formation and injection schedule along with piston bowl design to optimize combustion efficiency, air utilization, heat transfer, emission, and BTE. The methodology uses a suite of tools to optimize engine performance, including 1D engine simulation, high-fidelity CFD, and lab-scale fluid mechanic experiments. First, a wide range of engine operating conditions are analyzed using 1-D engine simulations in GT Power to thoroughly define a baseline for the chosen advanced engine concept; secondly, an optimization and down-select step is completed where further improvements in engine geometries and spray configurations are considered.

High-fidelity overall vehicle simulations require efficient computational routines for the various vehicle subsystems. Typically, these simulations blend theoretical dynamic system models with empirical results to produce computer models which execute efficiently. Provided that the internal combustion engine is a dominant source of vehicle vibration, knowledge of its dynamic characteristics throughout its operating envelope is essential to effectively predict vehicle response. The present experimental study was undertaken to determine the rigid body modal content of engine block vibration of a modern, heavy-duty Diesel engine. Experiments were conducted on an in-line six-cylinder Diesel engine (nominally rated at 470 BHP) which is used in both commercial Class-VIII trucks, and on/off-road military applications. The engine was mounted on multi-axis force transducers in a dynamometer test cell in the standard three-point configuration.