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An advanced exhaust aftertreatment system is characterized following end-of-life catalyst aging to meet final Tier 4 off-highway emission requirements. This system consists of a fuel dosing system, mixing elements, fuel reformer, lean NOx trap (LNT), diesel particulate filter (DPF), and a selective catalytic reduction (SCR) catalyst. The fuel reformer is used to generate hydrogen (H2) and carbon monoxide (CO) from injected diesel fuel. These reductants are used to regenerate and desulfate the LNT catalyst. NOx emissions are reduced using the combination of the LNT and SCR catalysts. During LNT regeneration, ammonia (NH3) is intentionally released from the LNT and stored on the downstream SCR catalyst to further reduce NOx that passed through the LNT catalyst. This paper addresses system durability as the catalysts were aged to 500 desulfation events using an off-highway diesel engine.

The identification of the dominant noise sources in diesel engines and the assessment of their contribution to far-field noise is a process that can involve both fired and motored testing. In the present work, the cross-spectral densities of signals from cylinder pressure transducers, accelerometers mounted on the engine surface, and microphones (in the near and far fields), were used to identify dominant noise sources and estimate the transfer paths from the various “inputs” (i.e., the cylinder pressures, the accelerometers and the near field microphones) to the far field microphones. The method is based on singular value decomposition of the input cross-spectral matrix to relate the input measurements to independent virtual sources. The frequencies at which a particular input is strongly affected by an independent source are highlighted, and with knowledge of transducer locations, inferences can be drawn as to possible noise source mechanisms.

Diesel Cylinder Deactivation (CDA) has been shown in previous work to increase exhaust temperatures, improve fuel efficiency, and reduce engine-out NOx for engine loads up to 3 bar BMEP. The purpose of this study is to determine whether or not the turbocharger needs to be altered when implementing CDA on a diesel engine. This study investigates the effect of CDA on exhaust temperature, fuel efficiency, and turbocharger performance in a 15L heavy-duty diesel engine under low-load (0-3 bar BMEP) steady-state operating conditions. Two calibration strategies were evaluated. First, a “stay-hot” thermal management strategy in which CDA was used to increase exhaust temperature and reduce fuel consumption. Next, a “get-hot” strategy where CDA and elevated idle speed was used to increase exhaust temperature and exhaust enthalpy for rapid aftertreatment warm-up.

Component sound quality is an important factor in the design of competitive diesel engines. One component noise that causes complaints is the gear rattle that originates in the front-of-engine gear train which drives the fuel pump and other accessories. The rattle is caused by repeated tooth impacts resulting from fluctuations in differential torsional acceleration of the driving gears. These impacts generate a broadband, impulsive noise that is often perceived as annoying. In most previous work, the overall sound quality of diesel engines has been considered without specifically focusing on predicting the perception of gear rattle. Gear rattle level has been quantified based on angular acceleration measurements, but those measurements can be difficult to perform. Here, the emphasis was on developing a metric based on subjective testing of the perception of gear rattle.

This paper presents a simulation model for the analysis of internal gear ring pumps. The model follows a multi domain simulation approach comprising sub-models for parametric geometry generation, fluid dynamic simulation, numerical calculation of characteristic geometry data and CAD/FEM integration. The sub-models are interacting in different domains and relevant design and simulation parameters are accessible in a central, easy to handle graphical user interface. The potentials of the described tool are represented by simulation results for both steady state and transient pump operating conditions and by their correlation with measured data. Although the presented approach is suitable to all applications of gear ring pumps, a particular focus is given to hydraulic actuation systems used in automotive drivetrain applications.

In long-duration, closed human habitats in space that include crop growth, one challenge that is faced while designing a candidate waste processor is the composition of solid-waste loads, which include human waste, packaging and food-processing materials, crop spoilage, and plant residues. In this work, a new modeling tool is developed to characterize crop residues and food wastes based on diet in order to support the design of solid-waste technologies for closed systems. The model predicts amounts of crop residues and food wastes due to food processing, crop harvests, and edible spoilage. To support the design of solid-waste technologies, the generation of crop residues and food wastes was characterized for a 600-day mission to Mars using integrated menu, crop, and waste models. The three sources of plant residues and food waste are identified to be food processors, crop harvests, and edible spoilage.

Results of computations of flows, sprays and combustion performed in an optically- accessible Diesel engine are presented. These computed results are compared with measured values of chamber pressure, liquid penetration, and soot distribution, deduced from flame luminosity photographs obtained in the engine at Sandia National Laboratories and reported in the literature. The computations were performed for two operating conditions representing low load and high load conditions as reported in the experimental work. The computed and measured peak pressures agree within 5% for both the low load and the high load conditions. The heat release rates derived from the computations are consistent with expectations for Diesel combustion with a premixed phase of heat release and then a diffusion phase. The computed soot distribution shows noticeable differences from the measured one.

Dynamics of machine tool components play a critical role in the outcome of machining processes. This paper addresses several important issues on machine tool and machining dynamics. It illustrates the dynamic behavior of structural components under operating conditions and presents an improved technique for modeling structural non-linearity. It also describes spindle modeling capability that has been developed to predict dynamic and thermal characteristics of spindle systems. Finally, the paper discusses the impact of non-linear dynamics on machining stability.

This paper presents in-process monitoring and control based on a novel ultrasonic sensing technique. The developed ultrasonic system provides non-contact measurement of surface roughness, which is applicable to wet machining environments. The utility and robustness of the technique are demonstrated through applications to different processes and materials. In-process surface roughness monitoring capability of the system is also shown along with its potential to monitor flank wear conditions. The result of in-process surface roughness control implementation based on the developed technique shows the control scheme is able to maintain consistent surface roughness values regardless of the tool wear state.

An advanced exhaust aftertreatment system is being developed using a fuel dosing system, mixing elements, fuel reformer, lean NOx trap (LNT), diesel particulate filter (DPF) and a selective catalytic reduction (SCR) catalyst arranged in series for both on- and off- highway diesel engines to meet the upcoming emissions regulations. This system utilizes a fuel reformer to generate hydrogen (H2) and carbon monoxide (CO) from injected diesel fuel. These reductants are used to regenerate and desulfate the LNT catalyst. NOx emissions are reduced using the combination of the LNT and SCR catalysts. During LNT regeneration, ammonia is intentionally released from the LNT and stored on the downstream SCR catalyst to further reduce NOx that passed through the LNT catalyst. This paper addresses LNT and SCR catalyst degradation as these were subjected to 150 desulfation events using a pre-production 2007 medium heavy-duty, on-highway diesel engine.

In this paper, a wall-modified interactive flamelet model is developed for improving the modeling of Diesel combustion. The objective is to include the effects of wall heat loss on the transient flame structure. The essential idea is to compute several flamelets with several representative enthalpy defects which account for wall heat loss. Then, the averaged flamelet profile can be obtained through a linear fit between the flamelets according to the enthalpy defect of the local gas which results from the wall heat loss. The enthalpy defect is estimated as the difference between the enthalpy in a flamelet without wall heat loss, which would correspond to the enthalpy in the gas without wall heat loss, and the gas with wall heat loss. The improved model is applied to model combustion in a Diesel engine. In the application, two flamelets, one without wall heat loss and one with wall heat loss, are considered.

Swirl in Diesel engines is known to be an important parameter that affects the mixing of the fuel jets, heat release, emissions, and overall engine performance. The changes may be brought about through interactions of the swirling flow field with the spray and through modifications of the flow field. The purpose of this paper is to investigate the interaction of the swirl with sprays in a Diesel engine through a computational study. A multi-dimensional model for flows, sprays, and combustion in engines is employed. Results from computations are reported with varying levels of swirl and initial turbulence in two typical Diesel engine geometries. It is shown that there is an optimal level of swirl for each geometry that results from a balance between increased jet surface area and, hence, mixing rates and utilization of air in the chamber.

A special vehicle dynamometer has been developed that allows engineers to evaluate driveline components and control algorithms for advanced, electrically-assisted drive systems on commercial vehicles. This dynamometer allows objective measurements of performance, fuel economy, and exhaust emissions, while the full vehicle is operated over a specified driving cycle. This system can be used to exercise the electric motor, engine, transmission and battery systems on Medium Duty Hybrid Trucks - in regeneration as well as power mode - all indoors and in a controlled, repeatable environment. This paper will provide descriptions of the operating goals, control features, and results of testing with this dynamometer. Once the various parameters have been optimized for fuel and emissions performance in this facility, the vehicle can be evaluated where it counts - on the road.

The standard model for predicting the outcome of drop-drop collisions in sprays is one developed based on measurements in rain drops under atmospheric pressure conditions. This model includes the possible outcomes of grazing collisions and coalescence. Recent measurements with hydrocarbon drops and at higher pressure (up to 12 bar) indicate the possibility of additional outcomes: bounce, reflexive separation and drop shattering. The measurements also indicate that the Weber number range over which bounce occurs is dependent on the gas pressure. The probability of a drop-drop collision resulting in bounce increases with gas pressure. A composite model that includes all these outcomes as possibilities is employed to carry out computations in a constant volume chamber and in a Diesel engine. A sub-model for bounce that includes the pressure effects is also part of the composite model.

In recent years, there has been an interest in early-injection Diesel engines as it has the potential of achieving a more homogeneous and leaner mixture close to top-dead-center (TDC) compared to standard Diesel engines. The more homogeneous mixture may result in reduced NOx and soot emissions and higher efficiency. Diesel engines in which a homogeneous mixture is achieved close to TDC are known as Homogenous Charge Compression Ignition (HCCI) engines. PREmixed lean DIesel Combustion (PREDIC) engines in which the start of fuel injection is considerably advanced in comparison with that of the standard Diesel engine is an attempt to achieve a mode of operation close to HCCI. Earlier studies have shown that in a PREDIC engine, the fuel injection timing affects the mixture formation and hence influences combustion and pollutant formation.

In Diesel engines, the vapor phase of the fuel jet is known to impinge on the walls. This impingement is likely to have an effect on mixing characteristics, the structure of the diffusion flame and on pollutant formation and oxidation. These effects have not been studied in detail in the literature. In this work, the structure of a laminar wall jet that is generated from the impingement of a free laminar jet on a wall is discussed. We study the laminar jet with the belief that the local structure of the reaction zone in the turbulent reacting jet is that of a laminar flame. Results from non-reacting and reacting jets will be presented. In the case of the non-reacting jets, the focus of the inquiry is on assessing the accuracy of the computed results by comparing them with analytical results. Velocity profiles in the wall jet, growth rates of the half-width of the jet and penetration rates are presented.

Diesel exhaust aftertreatment systems are required for meeting Final Tier 4 emission regulations. This paper addresses an aftertreatment system designed to meet the Final Tier 4 emission standards for nonroad vehicle markets. The aftertreatment system consists of a fuel dosing system, mixing elements, fuel vaporizer, fuel reformer, lean NOx trap (LNT), diesel particulate filter (DPF), and an optional selective catalytic reduction (SCR) catalyst. Aftertreatment system performance, both with and without the SCR, was characterized in an engine dynamometer test cell, using a 4.5 liter, pre-production diesel engine. The engine out NOx nominally ranged between 1.6 and 2.0 g/kW-hr while all operating modes ranged between 1.2 and 2.8 g/kW-hr. The engine out particulate matter was calibrated to approximately 0.1 g/kW-hr for various power ratings. Three engine power ratings of 104 kW, 85 kW and 78 kW were evaluated.

Wideband Acoustical Holography (WBH), which is a monopole-based, equivalent source procedure (J. Hald, “Wideband Acoustical Holography,” INTER-NOISE 2014), has proven to offer accurate noise source visualization results in experiments with a simple noise source: e.g., a loudspeaker (T. Shi, Y. Liu, J.S. Bolton, “The Use of Wideband Holography for Noise Source Visualization”, NOISE-CON 2016). From a previous study, it was found that the advantage of this procedure is the ability to optimize the solution in the case of an under-determined system: i.e., when the number of measurements is much smaller than the number of parameters that must be estimated in the model. In the present work, a diesel engine noise source was measured by using one set of measurements from a thirty-five channel combo-array placed in front of the engine.

A simulation framework with a validated system model capable of estimating fuel consumption is a valuable tool in analysis and design of the hybrid vehicles. In particular, the framework can be used for (1) benchmarking the fuel economy achievable from alternate hybrid powertrain technologies, (2) investigating sensitivity of fuel savings with respect to design parameters (for example, component sizing), and (3) evaluating the performance of various supervisory control algorithms for energy management. This paper describes such a simulation framework that can be used to predict fuel economy of series hydraulic hybrid vehicle for any specified driver demand schedule (drive cycle), developed in MATLAB/Simulink. The key components of the series hydraulic hybrid vehicle are modeled using a combination of first principles and empirical data. A simplified driver model is included to follow the specified drive cycle.

Diesel engine cylinder deactivation (CDA) can be used to reduce petroleum consumption and greenhouse gas (GHG) emissions of the global freight transportation system. Heavy duty trucks require complex exhaust aftertreatment (A/T) in order to meet stringent emission regulations. Efficient reduction of engine-out emissions require a certain A/T system temperature range, which is achieved by thermal management via control of engine exhaust flow and temperature. Fuel efficient thermal management is a significant challenge, particularly during cold start, extended idle, urban driving, and vehicle operation in cold ambient conditions. CDA results in airflow reductions at low loads. Airflow reductions generally result in higher exhaust gas temperatures and lower exhaust flow rates, which are beneficial for maintaining already elevated component temperatures. Airflow reductions also reduce pumping work, which improves fuel efficiency.