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Computational Fluid Dynamics is nowadays largely employed as an effective optimization tool in the automotive industry, especially for what concerns aerodynamic design driven by critical factors such as the engine cooling system optimization and the reduction of drag forces, both limited by continuously changing stylistic constraints. The Ahmed reference model is a generic car-type bluff body with a slant back, which is frequently used as a benchmark test case by industrial as well as academic researchers, in order to investigate the performances of different turbulence modeling approaches. In spite of its relatively simple geometry, the Ahmed model possesses many of the typical aerodynamic features of a modern passenger car - a bluff body with separated boundary layers, recirculating flows and complex three-dimensional wake structures.

The paper presents a study of a key-element in the mixture preparation process. A typical common-rail (CR) high-pressure fuel injector was fitted with a prototype injector nozzle with atomizer bores of a particular conical layout. It is demonstrated within certain layout limits, that a considerable enhancement can be obtained for the secondary break-up of the hard-core fluid sprays produced by the nozzle. The impact on the combustion process is examined in terms of pressure and heat release as well as of the engine-out pollutant emission. The results are compared to those of an earlier developed CR high-pressure injector nozzle. The atomization behavior of the prototype nozzle is illustrated through experimental results in terms of engine-out emissions from a 1.3-liter turbo-charged passenger car diesel engine. The detailed spray behavior is visualized on a component test rig by use of specially developed optical visualization techniques.

In this paper a numerical analysis is carried out of the flow characteristics in the intake system of a high performance engine. To this aim, the experimental flow bench results - obtained in tests performed on a Ducati Corse 4 valves racing engine head and presented in the parallel work [1] - are compared with the numerical ones. In [1] an experimental analysis was performed to evaluate the influence, on the flow characteristics in the intake system of a high performance 4 stroke - 4 valve internal combustion engine Notwithstanding the macroscopic meaning of the measured global coefficients Cd (Discharge Coefficient) and Nt (Tumble Number), the comparative analysis of their respective trends allowed some hypotheses to be drawn on the flow development internally to intake system ducts. In order to confirm the conclusions drawn in [1] and to reach a deeper insight in the flow characteristics, numerical simulations were performed.

In the future generation of low consumption SI-engine layouts, it has become necessary to reduce costs as well as the complexity level and, increase the system reliability by the latter. To avoid driving the GDI-system in the critical, very lean stratified operation mode without losing the fuel consumption benefit, a solution is suggested, which combines a fully variable valve control system with a low level, robust GDI combustion layout. The first part of the present paper presents the latest development in the field of high precision multi-hole GDI injector spray nozzles. The basic aspects of mixture preparation with multi-hole gasoline atomizers are highlighted and their spray behavior compared to that of the current swirl atomizer nozzle. The second part of the paper presents primary optimization of a largely homogeneous GDI combustion layout combined with a fully variable valve timing control system including complete cylinder de-activation.

The first part of the paper gives an overview of the current results obtained with the first-generation of GDI-powered vehicles launched on the European market. In view of the rather limited success in fuel consumption gain the second-generation of very lean stratified layouts has begun, but this process requires the development and application of new high-level analysis tools. A possible high performance approach is the multi-purpose use of 3-D numerical simulation both in the development and the engine control strategy calibration phases. The development of a small 1.6 liter lean stratified engine project was chosen to demonstrate the dual application capability of the NCF-3D simulation tool. The paper continues with a description of the engine application frame, the basic features of the NCF-3D simulation tool and the latest enhancements made to combustion and fuel composition models within the software frame.

The first part of the paper gives an overview of the current status in fuel consumption gain of the GDI-vehicles previously launched on the European market. In order to increase the potential for a further gain in specific fuel consumption the behaviour of 3 different combustion chamber layouts are studied. The chamber layouts are aimed to adapt as well as possible to the particular requirements for application to a small displacement/small bore engine working in stratified lean conditions. The paper continues with a description of the application that shows the different steps of a structured optimisation methodology for a 1.2 litre, small bore 4-cylinder engine. The applications of an air-motion-guided and a wall-guided layout with a mechanically actuated valve train to the same combustion chamber are discussed. The potential of the air-motion-guided concept is enhanced through the introduction of an electromagnetic fully variable valve train.

The suggestions for upcoming Euro 2000 clean air act puts an increasing legislative pressure for lower specific fuel consumption in order to reduce the emission of CO2 and thereby decrease the impact of the “green house” effect. One of the possible suggestions to meet these requirements for SI-engines is the gasoline direct injected (GDI) power unit. One of the key points of the success of a layout of a GDI system is the optimization of the fuel injector and combustion chamber charge formation parameters. A brief description of the basic GDI-system used during the study is given. Hereafter are outlined the computational and experimental optimization tools which have been used to produce, on a reasonable industrial time scale, the main indications to optimize the design of a given injector/chamber configuration. The paper discusses in detail the results produced by the latest enhancements introduced into the 3D multi-phase computational approach, NCF-3D.

The first part of the paper outlines the main potential advantages of the direct fuel injection concept and describes the overall layout of a system in which the keystones are a piston rotary fuel delivery pump with integrated pressure regulation and electromechanical fast responding fuel injectors. Three different nozzle designs are discussed, a divergent pintle solid cone, a pintle hollow cone swirl layout and a closed cap multijet design. In the second part of the paper the used experimental high pressure dynamic test equipment is discussed. Then the results obtained by the use of phase illuminated visualisation techniques and phase Doppler analysis as well as by a 3D CFD approach are presented. The paper concludes by relating the spray patterns and the associated droplet penetration velocities, produced by the different nozzle types, to the combustion chamber layout and to the possible manufacturing precision requirements for each nozzle type.