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Three integration strategies are developed and tested for the stiff, ordinary differential equation (ODE) integrators used to solve the fully coupled multizone chemical kinetics model. Two of the strategies tested are found to provide more than an order of magnitude of improvement over the original, basic level of usage for the stiff ODE solver. One of the faster strategies uses a decoupled, or segregated, multizone model to generate an approximate Jacobian. This approach yields a 35-fold reduction in the computational cost for a 20 zone model. Using the same approximate Jacobian as a preconditioner for an iterative Krylov-type linear system solver, the second improved strategy achieves a 75-fold reduction in the computational cost for a 20 zone model. The faster strategies achieve their cost savings with no significant loss of accuracy.

The effect of the shape of the EOI was investigated through a pressure-modulated injection system in order to improve the understanding of the last portion of the traditional diesel diffusion combustion process. Here, the combustion recession at EOI is when the combustion of a mixing controlled diesel jet recedes backwards toward the fuel injector nozzle orifice. Combustion recession was observed using combustion luminosity imaging filtered at 309 nm to capture OH* chemiluminescence and 430 nm to capture CH* chemiluminescence, although soot Natural Luminosity (NL) will also be visible in these measurements. Experimental spray vessel results show that for relatively slow EOI decelerations below 1 ×106 to 2 ×106 m/s2, combustion strongly recesses completely back to the nozzle in both OH* and CH*/NL imaging. 1-D jet mixing calculations add support that this strong recession is indeed fuel rich.

Detailed exhaust speciation measurements were made on an HCCI engine fueled with iso-octane over a range of fueling rates, and over a range of fuel-stratification levels. Fully premixed fueling was used for the fueling sweep. This sweep extended from a fuel/air equivalence ratio (ϕ) of 0.28, which is sufficiently high to achieve a combustion efficiency of 96%, down to a below-idle fueling rate of ϕ = 0.08, with a combustion efficiency of only 55%. The stratification sweep was conducted at an idle fueling rate, using an 8-hole GDI injector to vary stratification from well-mixed conditions for an early start of injection (SOI) (40°CA) to highly stratified conditions for an SOI well up the compression stroke (325°CA, 35°bTDC-compression). The engine speed was 1200 rpm. At each operating condition, exhaust samples were collected and analyzed by GC-FID for the C1 and C2 hydrocarbon (HC) species and by GC-MS for all other species except formaldehyde and acetaldehyde.

One way to increase the load range in an HCCI engine is to increase boost pressure. In this modeling study, we investigate the effect of increased boost pressure on the fuel chemistry in an HCCI engine. Computed results of HCCI combustion are compared to experimental results in a HCCI engine. We examine the influence of boost pressure using a number of different detailed chemical kinetic models - representing both pure compounds (methylcyclohexane, cyclohexane, iso-octane and n-heptane) and multi-component models (primary reference fuel model and gasoline surrogate fuel model). We examine how the model predictions are altered by increased fueling, as well as reaction rate variation, and the inclusion of residuals in our calculations. In this study, we probe the low temperature chemistry (LTC) region and examine the chemistry responsible for the low-temperature heat release (LTHR) for wide ranges of intake boost pressure.

This paper investigates flow and combustion in a full-cycle simulation of a four-stroke, three-valve HCCI engine by visualizing the flow with pathlines. Pathlines trace massless particles in a transient flow field. In addition to visualization, pathlines are used here to trace the history, or evolution, of flow fields and species. In this study evolution is followed from the intake port through combustion. Pathline analysis follows packets of intake charge in time and space from induction through combustion. The local scalar fields traversed by the individual packets in terms of velocity magnitude, turbulence, species concentration and temperatures are extracted from the simulation results. The results show how the intake event establishes local chemical and thermal environments in-cylinder and how the species respond (chemically react) to the local field.

Isopentanol is an advanced biofuel that can be produced by micro-organisms through genetically engineered metabolic pathways. Compared to the more frequently studied ethanol, isopentanol's molecular structure has a longer carbon chain and includes a methyl branch. Its volumetric energy density is over 30% higher than ethanol, and it is less hygroscopic. Some fundamental combustion properties of isopentanol in an HCCI engine have been characterized in a recent study by Yang and Dec (SAE 2010-01-2164). They found that for typical HCCI operating conditions, isopentanol lacks two-stage ignition properties, yet it has a higher HCCI reactivity than gasoline. The amount of intermediate temperature heat release (ITHR) is an important fuel property, and having sufficient ITHR is critical for HCCI operation without knock at high loads using intake-pressure boosting. Isopentanol shows considerable ITHR, and the amount of ITHR increases with boost, similar to gasoline.

How will a mechanic troubleshoot the heavy duty vehicle of the future? Will he or she have to be both retriever and integrator of data collected from multiple black boxes on the vehicle? How many tools will it take? Is there a definition of a vehicle system “diagnostic environment” that needs to be developed in order to create a solution to this problem? This paper will attempt to create the system focus for vehicle diagnostics that is required if this industry is to successfully produce the integrated electronic vehicle of the future. Both the on-board and off-board requirements of the diagnostic environment will be examined.

Previous studies have shown that fuels with higher laminar flame speed also have increased tolerance to EGR dilution. In this work, the effects of fuel laminar flame speed on both lean and EGR dilute spark ignition combustion stability were examined. Fuels blends of pure components (iso-octane, n-heptane, toluene, ethanol, and methanol) were derived at two levels of laminar flame speed. Each fuel blend was tested in a single-cylinder spark-ignition engine under both lean-out and EGR dilution sweeps until the coefficient of variance of indicated mean effective pressure increased above thresholds of 3% and 5%. The relative importance of fuel laminar flame speed to changes to engine design parameters (spark ignition energy, tumble ratio, and port vs. direct injection) was also assessed.

This paper describes a study to demonstrate the feasibility of developing an acoustic encapsulation to reduce airborne noise from a commercial diesel engine. First, the various sources of noise from the engine were identified using Nearfield Acoustical Holography (NAH). Detailed NAH measurements were conducted on the four sides of the engine in an engine test cell. The main sources of noise from the engine were ranked and identified within the frequency ranges of interest. Experimental modal analysis was conducted on the oil pan and front cover plate of the engine to reveal correlations of structural vibration results with the data from the NAH. The second phase of the study involved the design and fabrication of the acoustical encapsulation (noise covers) for the engine in a test cell to satisfy the requirements of space, cost and performance constraints. The acoustical materials for the enclosure were selected to meet the frequency and temperature ranges of interest.

Caterpillar Fuel Systems is developing a family of next generation electronic unit injectors that provide the fundamental injection characteristics necessary for emissions and performance improvements for future direct-injection diesel engines. This paper describes the development and design of the mechanically actuated version of Caterpillar's advanced electronic unit injector fuel system to meet the engine customer driven requirements for enhanced injection characteristics with reliability and durability improvements.

The ignition delay times of primary reference fuel (PRF) and toluene mixtures have been measured behind the reflected shock waves. The range of experiments covered combustion of fuel in diluted argon for stoichiometric mixtures, pressures of 2.5 atm, temperatures from 1200-1600 K, 0.4% of fuel concentration. The ignition delay times of n-heptane increased with the addition of toluene. However the ignition delay times of iso-octane decreased with the addition of toluene from 0 to 50% and increased from 50 to 100%. A detailed kinetic model with cross reactions considered in this study can not reproduce the trend of ignition delay times for iso-octane/toluene mixtures. From the reaction path analysis, it was suggested that cross reactions between alkenes and aromatics are required to account for these experimental results.

Homogenous Charge Compression Ignition (HCCI) is a new engine technology with fundamental differences over conventional engines. HCCI engines are intrinsically fuel flexible and can run on low-grade fuels as long as the fuel can be heated to the point of ignition. In particular, HCCI engines can run on “wet ethanol:” ethanol-in-water mixtures with high concentration of water, such as the high water content ethanol-in-water mixture that results from fermentation of corn mash. Considering that much of the energy required for processing fermented ethanol is spent in distillation and dehydration, direct use of wet ethanol in HCCI engines considerably shifts the energy balance in favor of ethanol.

The ignition delay times of toluene-oxygen-argon mixtures with fuel equivalence ratios from 0.5 to 1.5 and concentrations of toluene from 0.1 to 2.0% were measured behind reflected shock waves for temperatures 1270 to 1755 K and at a pressure of 2.4 ± 0.7 atm. A detailed chemical kinetic model has been developed on the basis of a kinetic mechanism proposed by Pitz et al. [1] to reproduce our experimental results as well as some literature data obtained in other shock tubes at pressures from 1.1 to 50 atm. It is found that the present chemical kinetic model could give better agreement on the pressure dependence of the ignition delay times than the previously proposed kinetic models.

This paper documents an inverse visible element Rayleigh integral (VERI) approach. The VERI is a fast though approximate method for predicting sound radiation that can be used in the place of the boundary element method. This paper extends the method by applying it to the inverse problem where the VERI is used to generate the acoustic transfer matrix relating the velocity on the surface to measurement points. Given measured pressures, the inverse VERI can be used to reconstruct the vibration of a radiating surface. Results from an engine cover and diesel engine indicate that the method can be used to reliably quantify the sound power and also approximate directivity.

The critical particle size for a high-pressure injection system was determined. Various double-cut test dusts ranging from 0 to 5 μm to 10 to 20 μm were evaluated to determine which test dust caused the high-pressure system to fail. With the exception of the 0- to 5-μm test dust, all test dust ranges caused failure in the high-pressure injection system. Analysis of these evaluations revealed that the critical particle size, in initiating significant abrasive wear, is 6 to 7 μm. Wear curve formulas were generated for each evaluation. A formula was derived that allows the user to determine if the fuel filter effluent will cause harmful damage to the fuel system based on the number of 5-, 10-, and 15-μm particles per milliliter present. A methodology was developed to evaluate fuel filter performance as related to engine operating conditions. The abrasive methodology can evaluate online filter efficiency and associated wear in a high-pressure injection system.

Joint strength of a vibration welded air intake manifold has been optimized by controlling the process parameters. Key process parameters are: Clamp pressure, bead melt down displacement and vibration amplitude. The present study has investigated the combined effect of the vibration welding process parameters on the weld joint strength of a manifold by using a factorial DOE (Design of Experiment) with center points. The result of the DOE study revealed that the burst strength can vary as much as 50% across the process window investigated. Response surface of strength, which was developed as a function of the process variables, can be used for process control in the production plant. The weld strength values of Nylon 6 and Nylon 66 materials are also compared across the wide range of the process window.

A new Computational Fluid Dynamics (CFD) code has been developed in order to overcome the deficiencies of traditional grid generation and mesh motion methods. The new code uses a modified cut-cell Cartesian technique that eliminates the need for the computational grid to coincide with the geometry of interest. The code also includes state-of-the-art numerical techniques and sub-models for simulating the complex physical and chemical processes that occur in engines. Features such as shared and distributed memory parallelization, a multigrid pressure solver and user-specified grid embedding allow for efficient simulations while maintaining the grid resolution necessary for accurate engine modeling. In addition, a new Adaptive Grid Embedding (AGE) technique has been developed and implemented. Sub-models for turbulence, spray injection, spray breakup, liquid drop dynamics, ignition, combustion and emissions are also included in the code.

The development of surrogate mixtures that represent gasoline combustion behavior is reviewed. Combustion chemistry behavioral targets that a surrogate should accurately reproduce, particularly for emulating homogeneous charge compression ignition (HCCI) operation, are carefully identified. Both short and long term research needs to support development of more robust surrogate fuel compositions are described. Candidate component species are identified and the status of present chemical kinetic models for these components and their interactions are discussed. Recommendations are made for the initial components to be included in gasoline surrogates for near term development. Components that can be added to refine predictions and to include additional behavioral targets are identified as well. Thermodynamic, thermochemical and transport properties that require further investigation are discussed.

Multi-zone CFD simulations with detailed kinetics were used to model iso-octane HCCI experiments performed on a single-cylinder research engine. The modeling goals were to validate the method (multi-zone combustion modeling) and the reaction mechanism (LLNL 857 species iso-octane) by comparing model results to detailed exhaust speciation data, which was obtained with gas chromatography. The model is compared to experiments run at 1200 RPM and 1.35 bar boost pressure over an equivalence ratio range from 0.08 to 0.28. Fuel was introduced far upstream to ensure fuel and air homogeneity prior to entering the 13.8:1 compression ratio, shallow-bowl combustion chamber of this 4-stroke engine. The CFD grid incorporated a very detailed representation of the crevices, including the top-land ring crevice and head-gasket crevice. The ring crevice is resolved all the way into the ring pocket volume. The detailed grid was required to capture regions where emission species are formed and retained.

A general combustion model, in the context of large eddy simulations, was developed to simulate the full range of combustion in conventional diesel-type and HCCI-type diesels. The combustion model consisted of a Chemkin sub-model and an Extended Flamelet Time Scale (EFTS) sub-model. Specifically, Chemkin was used to simulate auto-ignition process. In the post-ignition phase, the combustion model was switched to EFTS. In the EFTS sub-model, combustion was assumed to be a combination of two elementary combustion modes: homogeneous combustion and flamelet combustion. The combustion index acted as a weighting factor blending the contributions from these two modes. The Chemkin sub-model neglected the subgrid scale turbulence-chemistry interactions whereas the EFTS model took them into account through a presumed PDF approach. The model was used to simulate an early injection mode of a Cummins DI diesel engine and a mode of a Caterpillar DI diesel engine.