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Heat transfer is one of the largest causes of exergy destruction in modern engines. In this paper, exergy distribution modeling was used to determine the potential of reduced engine heat transfer to provide significant gains in engine efficiency. As known from prior work, of itself, reducing heat transfer creates only a small increase in efficiency-most of the exergy is redirected into the exhaust stream-requiring both mechanical and thermal recovery of the exhaust exergy. Mechanical regeneration, through turbocharging and over-expansion, can lead to efficiencies exceeding 50%. Adding thermal regeneration, through high enthalpy steam injection or a bottoming cycle, can increase the efficiency potential to approximately 60%. With implementation of both mechanical and thermal regeneration, the only remaining cause of substantial exergy destruction is the combustion process.

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.

In-cylinder pre-processing (or recompression reaction) of direct-injected fuel during the negative valve overlap period of a retention-strategy HCCI engine is investigated for extension of the low-load limit of operation. Experimental studies of three variables (compression ratio, pilot injection timing, and pilot injection amount) were conducted in order to optimize the effects of recompression reaction by changing the sensible and chemical energy environment during recompression. The results from compression ratio variation show that there exist optimum values of equivalence ratio and extent of recompression reaction, which expand the low-load operating region. The pilot injection timing variation demonstrates good controllability of the extent of recompression reaction by effectively changing the in-cylinder residence time of the pilot-injected fuel.

We have converted a Caterpillar 3406 natural gas spark ignited engine to HCCI mode and used it as a test bed for demonstrating advanced control methodologies. Converting the engine required modification of most engine systems: piston geometry, starting, fueling, boosting, and (most importantly) controls. We implemented a thermal management system consisting of a recuperator that transfers heat from exhaust to intake gases and a dual intake manifold that permits precise cylinder-by-cylinder ignition control. Advanced control methodologies are used for (1) minimizing cylinder-to-cylinder combustion timing differences caused by small variations in temperature or compression ratio; (2) finding the combustion timing that minimizes fuel consumption; and (3) tuning the controller parameters to improve transient response.

We have developed a methodology for predicting combustion and emissions in a Homogeneous Charge Compression Ignition (HCCI) Engine. This methodology combines a detailed fluid mechanics code with a detailed chemical kinetics code. Instead of directly linking the two codes, which would require an extremely long computational time, the methodology consists of first running the fluid mechanics code to obtain temperature profiles as a function of time. These temperature profiles are then used as input to a multi-zone chemical kinetics code. The advantage of this procedure is that a small number of zones (10) is enough to obtain accurate results. This procedure achieves the benefits of linking the fluid mechanics and the chemical kinetics codes with a great reduction in the computational effort, to a level that can be handled with current computers.

This research investigates how the handling of mixing and heat transfer in a multi-zone kinetic solver affects the prediction of carbon monoxide and hydrocarbon emissions for simulations of HCCI engine combustion. A detailed kinetics multi-zone model is now more closely coordinated with the KIVA3V computational fluid dynamics code for simulation of the compression and expansion processes. The fluid mechanics is solved with high spatial and temporal resolution (40,000 cells). The chemistry is simulated with high temporal resolution, but low spatial resolution (20 computational zones). This paper presents comparison of simulation results using this enhanced multi-zone model to experimental data from an isooctane HCCI engine.

It has previously been shown experimentally and computationally that the process of Homogeneous Charge Compression Ignition (HCCI) is very dependent on the pre-combustion gas temperature field. This study looks in detail at how temperature fields can evolve by comparing results of two combustion chamber designs, a piston with a square bowl and a disk shaped piston, and relates these temperature fields to measured HCCI combustion durations. The contributions of combustion chamber surface area and turbulence levels to the gas temperature evolution are considered over the crank angle range from intake valve closure to top-dead-center. This is a CFD study, whose results were transformed into traditional analysis methods of convective heat transfer (q=h*A*ΔT) and boundary layers.

Cocktail shaker cooling is the commonly used term to describe heat transfer in a reciprocating hollow cylinder partially filled with a liquid. The sodium filled valve is a widely used application of this heat transfer concept. This paper presents information that may be useful in the design of cocktail shaker cooled pistons and valves. The design data are presented in nondimensional form using parameters typical of conventional convective heat transfer correlations. An illustrative problem for a piston is presented to show the application of the design data.

The dynamic stage of combustion - the intrinsic process for pushing the compression polytrope away from the expansion polytrope to generate the indicator work output of a piston engine - was studied to reveal the influence of the air/fuel ratio on the effectiveness with which the fuel was utilized. The results of tests carried out for this purpose, using a 12 liter diesel engine, were reported last year [SAE 1999-01-0517]. Presented here is an analytic interpretation of the data obtained for part-load operation at 1200 and 1800 rpm. A solution is thus provided for an inverse problem: deduction of information on the dynamic features of the exothermic process of combustion from measured pressure record. Provided thereby, in particular, is information on the effectiveness with which fuel was utilized in the course of this process - a parameter reflecting the effect of energy lost by heat transfer to the walls.