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Technical Paper

Effects of hole layout, braking torque and frictional heat on crack initiation from small holes in one-piece brake discs

2000-06-12
2000-05-0232
Brake discs have some holes in the flange for promoting heat dissipation as well as refreshing the pad surfaces. One-piece brake discs are desirable even for large sizes in order to reduce the production cost. However, cracks exceptionally occurred from some holes in the flange during braking under extremely severe test conditions for one-piece brake discs. On the other hand, no cracks were observed under the same condition for two-piece brake discs consisting of a hub and a flange. The objective of the present work is to show way cracks occur in the case of one-piece brake discs. Cyclic braking tests under extremely severe conditions were carried out using large one-piece brake discs having some hole in their flange. When the number of braking cycles was beyond 300, some tiny cracks occurring around holes were found. They grew in the radial direction of the brake discs.
Technical Paper

Effect of Gas Density and the Number of Injector Holes on the Air Flow Surrounding Non-Evaporating Transient Diesel Sprays

2001-03-05
2001-01-0532
The effect of ambient gas density and the number of injector holes on the characteristics of airflow surrounding non-evaporating transient diesel sprays inside a constant volume chamber were investigated using a 6-hole injector. Particle Image Velocimetry (PIV) was used to measure the gas velocities surrounding a spray plume as a function of space and time. A conical control surface surrounding the spray plume was chosen as a representative side entrainment surface. The positive normal velocities across the control surface of single-hole injection sprays were higher than those of 6-hole injection sprays. An abrupt increase in velocities tangential to the control surface near the chamber wall suggests that the recirculation of surrounding gas is accelerated by spray wall impingement.
Technical Paper

Development of Micro-Diesel Injector Nozzles via MEMS Technology and Effects on Spray Characteristics

2001-03-05
2001-01-0528
Micro-machined planar orifice nozzles have been developed and used with commercially produced diesel injection systems. Such a system may have the capability to improve the spray characteristics in DI diesel engines. The availability of a MEMS (Micro-Electro-Mechanical-Systems) processing sequence supported the construction of micro-planar orifice nozzles, and micro-systems technology was also employed in our macro-instrumentation. To demonstrate this process, fourteen MEMS nozzles were fabricated with deep X-ray lithography and electroplating technology. The circular orifice diameters were varied from 40 to 260 microns and the number of orifices varied from one to 169. Three plates with non-circular orifices were also fabricated to examine the effect of orifice shape on spray characteristics. These nozzles were then attached to commercial injectors and the associated injection systems were used for the spray experiments.
Technical Paper

Characteristics of Vaporizing Continuous Multi-Component Fuel Sprays in a Port Fuel Injection Gasoline Engine

2001-03-05
2001-01-1231
Vaporization models for continuous multi-component liquid sprays and liquid wall films are presented using a continuous thermodynamics formulation. The models were implemented in the KIVA3V-Release 2.0 code. The models are first applied to clarify the characteristics of vaporizing continuous multi-component liquid wall films and liquid drops, and then applied to numerically analyze a practical continuous multi-component fuel - gasoline behavior in a 4-valve port fuel injection (PFI) gasoline engine under warm conditions. Corresponding computations with single-component fuels are also performed and presented for comparison purposes. As compared to the results of its single-component counterpart, the vaporizing continuous multi-component fuel drop displays a larger vaporization rate initially and a smaller vaporization rate as it becomes more and more dominated by heavy species.
Technical Paper

The Effect of Fuel-Vapor Concentration on the Process of Initial Combustion and Soot Formation in a DI Diesel Engine Using LII and LIEF

2001-03-05
2001-01-1255
A phenomenological or empirical model based on experimental results obtained from various optical measurements is critical for the understanding of DI diesel combustion phenomena as well as for the improvement of its emission characteristics. Such a model could be realized by the application of advanced optical measurement, which is able to isolate a particular phenomenon amongst complicated physical and chemical interactions, to a DI diesel combustion field. The authors have conducted experimental studies to clarify the combustion characteristics of unsteady turbulent diffusion flames in relation to the soot formation and oxidation process in a small-sized DI diesel engine. In the present study, the effect of fuel vapor concentration on the process of early combustion and soot formation has been investigated using several optical measurements.
Technical Paper

Detailed Chemical Kinetic Modeling of Diesel Spray Combustion with Oxygenated Fuels

2001-03-05
2001-01-1262
This paper confirms a structure for the soot formation process inside a burning diesel jet plume of oxygenated fuels. An explanation of how the soot formation process changes by the use of oxygenated fuel in comparison with that for using a conventional diesel fuel, and why oxygenated fuel drastically suppresses the soot formation has been derived from the chemical kinetic analysis. A detailed chemical kinetic mechanism, which is combined with various proposed chemical kinetic models including normal paraffinic hydrocarbon oxidation, oxygenated hydrocarbon oxidation, and poly-aromatic hydrocarbon (PAH) formation, was developed in present study. The calculated results are presented to elucidate the influence of fuel mixture composition and fuel structure, especially relating to oxygenated fuels, on PAH formation. The analysis also provides a new insight into the initial soot formation process in terms of the temperature range of PAH formation.
Technical Paper

Effects of Alternative Fuels and Intake Port Geometry on HSDI Diesel Engine Performance and Emissions

2001-03-05
2001-01-0647
This research explored methods to reduce regulated emissions in a small-bore, direct-injection diesel engine. Swirl was used to influence mixing of the spray plumes, and alternative fuels were used to study the effects of oxygenated and water microemulsion diesel fuels on emissions. Air/fuel mixing enhancement was achieved in the running engine by blocking off a percentage of one of the two intake ports. The swirl was characterized at steady-state conditions with a flowbench and swirl meter. Swirl ratios of 1.85, 2.70, and 3.29 were studied in the engine tests at full load with engine speeds of 1303, 1757, and 1906 rev/min. Increased swirl was shown to have negative effects on emissions due to plume-to-plume interactions. Blends of No. 2 diesel and biodiesel were used to investigate the presence of oxygen in the fuel and its effects on regulated emissions. Pure No. 2 diesel fuel, a 15% and a 30% biodiesel blend (by weight) were used.
Technical Paper

Soot formation/oxidation and fuel-vapor concentration in a DI diesel engine using laser-sheet imaging method

2000-06-12
2000-05-0078
Four kinds of optical measurements were performed to investigate the process of soot formation and oxidation in a direct-injection (DI) diesel engine. Measurements were carried out in an optically accessible DI diesel engine that allows planar laser sheet for combustion diagnostics to enter the combustion chamber either horizontally or along the axis of the fuel jet. The temporal and spatial distribution of soot particles has been investigated using the laser- induced incandescence (LII) and high-speed direct photography. Fuel vapor concentration, which is directly linked to the soot formation process in diesel combustion, has been deduced from the images obtained by the measurements of laser shadowgraph and elastic Mie scattering. According to the experimental results, soot formation begins to occur near the injector nozzle in which a fuel-rich mixture is distributed with a homogeneous condition. LII signal is dominated by the fuel vapor concentration in initial combustion period.
Technical Paper

Mixing and soot formation processes in transient gas jet flame

2000-06-12
2000-05-0075
A transient gas jet and its flame are the most fundamental phenomena of a transient spray and its flame breaking out in a CI engine and an SI engine with the direct injection system. In the case of CNG and LNG engines, the fuel itself is just gaseous state. The 2-LIF technique was applied to the transient gas jet to obtain the mixing process between the surroundings and it, and the simultaneous application of LII and LIS techniques were applied to the transient gas jet flame to obtain the soot formation process.
Technical Paper

The structure analysis of diesel free spray with phase change~(Effect of viscosity change of vapor-phase fuel on the structure of diesel free spray)

2000-06-12
2000-05-0100
In this study, the purpose is placed in analysis the structure of diesel spray and, especially, making clear the mixture formation process in the evaporative diesel spray. The liquid fuel was injected from a single-hole nozzle (1/d = 1.0 mm/0.2 mm) into a constant-volume vessel possessing phenomena visualization under high pressure and temperature field. As for measurement method, in order to investigate liquid and vapor-phase of injected spray, exciplex fluorescence method was applied in the evaporative fuel spray. And the interested view region in injected spray is the downstream spray. For the minute investigation of spray flow, the liquid and vapor-phase region is taken with 35 mm still camera and CCD camera, respectively.
Technical Paper

A Sequential Fluid-Mechanic Chemical-Kinetic Model of Propane HCCI Combustion

2001-03-05
2001-01-1027
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.
Technical Paper

Effect of Injection Timing on Detailed Chemical Composition and Particulate Size Distributions of Diesel Exhaust

2003-05-19
2003-01-1794
An experimental study was carried out to investigate the effects of fuel injection timing on detailed chemical composition and size distributions of diesel particulate matter (PM) and regulated gaseous emissions in a modern heavy-duty D.I. diesel engine. These measurements were made for two different diesel fuels: No. 2 diesel (Fuel A) and ultra low sulfur diesel (Fuel B). A single-cylinder 2.3-liter D.I. diesel engine equipped with an electronically controlled unit injection system was used in the experiments. PM measurements were made with an enhanced full-dilution tunnel system at the Engine Research Center (ERC) of the University of Wisconsin-Madison (UW-Madison) [1, 2]. The engine was run under 2 selected modes (25% and 75% loads at 1200 rpm) of the California Air Resources Board (CARB) 8-mode test cycle.
Technical Paper

Effect of Fuel Composition on Combustion and Detailed Chemical/Physical Characteristics of Diesel Exhaust

2003-05-19
2003-01-1899
An experimental study was performed to investigate the effect of fuel composition on combustion, gaseous emissions, and detailed chemical composition and size distributions of diesel particulate matter (PM) in a modern heavy-duty diesel engine with the use of the enhanced full-dilution tunnel system of the Engine Research Center (ERC) of the UW-Madison. Detailed description of this system can be found in our previous reports [1,2]. The experiments were carried out on a single-cylinder 2.3-liter D.I. diesel engine equipped with an electronically controlled unit injection system. The operating conditions of the engine followed the California Air Resources Board (CARB) 8-mode test cycle. The fuels used in the current study include baseline No. 2 diesel (Fuel A: sulfur content = 352 ppm), ultra low sulfur diesel (Fuel B: sulfur content = 14 ppm), and Fisher-Tropsch (F-T) diesel (sulfur content = 0 ppm).
Technical Paper

Optimizing the University of Wisconsin's Parallel Hybrid-Electric Aluminum Intensive Vehicle

2000-03-06
2000-01-0593
The University of Wisconsin - Madison FutureCar Team has designed and built a lightweight, charge sustaining, parallel hybrid-electric vehicle for entry into the 1999 FutureCar Challenge. The base vehicle is a 1994 Mercury Sable Aluminum Intensive Vehicle (AIV), nicknamed the “Aluminum Cow,” weighing 1275 kg. The vehicle utilizes a high efficiency, Ford 1.8 liter, turbo-charged, direct-injection compression ignition engine. The goal is to achieve a combined FTP cycle fuel economy of 23.9 km/L (56 mpg) with California ULEV emissions levels while maintaining the full passenger/cargo room, appearance, and feel of a full-size car. Strategies to reduce the overall vehicle weight are discussed in detail. Dynamometer and experimental testing is used to verify performance gains.
Technical Paper

Potato Tuber Formation and Metabolism in the Spaceflight Environment

1996-07-01
961393
Five potato (Solanum tuberosum L.) leaf cuttings were flown on STS-73 in late October, 1995 as part of the 16-day USML-2 mission. Pre-flight studies were conducted to study tuber growth, determine carbohydrate concentrations and examine the developing starch grains within the tuber. In these tests, tubers attained a fresh weight of 1.4 g tuber-1 after 13 days. Tuber fresh mass was significantly correlated to tuber diameter. Greater than 60% of the tuber dry mass was starch and the starch grains varied in size from 2 to 40 mm in the long axis. For the flight experiment, cuttings were obtained from seven-week-old Norland potato plants, kept at 5°C for 12 hours then planted into arcillite in the ASTROCULTURE™ flight hardware. The flight package was loaded on-board the orbiter 22 hours prior to launch.
Technical Paper

Near Wall Interaction in Spray Impingement

1996-02-01
960863
The hydrodynamic details of droplet-droplet and droplet-liquid film interactions on solid surfaces are believed to have a significant role in spray impingement phenomena, yet details of this interaction have not been clearly identified. The interaction among the droplets during impact affects their residence time on the surface, spreading, and droplet and liquid film stability. After impact, droplet interactions affect droplet collisions, coalescence and liquid splashing, This interaction affects secondary atomization and the droplet dispersion characteristics of the impingement process. In this study, details of droplet-droplet and droplet-liquid film interactions in solid surface impingement have been visualized using high speed photography. The effects of these interactions on secondary atomization and droplet dispersion have been quantified.
Technical Paper

High Pressure Multiple Injection Spray Characteristics

1996-02-01
960860
In previous work, high injection pressures and multiple injections per engine stroke were shown to be effective at reducing the NOx and particulate emissions of DI Diesel engine combustion [1, 2]. A series of experiments were performed to study the effects of injection pressure, back pressure, and injection strategy on the spray characteristics for multiple injections. An injection system which was capable of multiple injections was used to introduce diesel fuel into a constant volume cold spray chamber. Parallel engine experiments were conducted using the same injectors as in this work [1, 2, 3]. In these engine tests, emissions (NOx and particulate) were measured. The engine experiments were used to develop the injector and chamber operating conditions for this work. The injection pressure was varied up to 90 MPa.
Technical Paper

Gas Efficient Liquid Atomization Using Micro-Machined Spray Nozzles

1996-02-01
960859
Improved atomization is important in fuel injection applications since atomization influences fuel-air mixing and vaporization rates. The present paper explores the use of low pressure gas/air injection and methods to achieve a dispersed two-phase flow to enhance the atomization process. Gas-driven twin-fluid atomization has been achieved by combining X-ray lithographic/micro-machining technology to mechanically disperse a driving gas into a liquid to be sprayed. This technique forces the gas through a designed pattern of micron sized holes thereby yielding a field of micro-bubbles immediately upstream of the < I mm. diameter discharge orifice. Precise control of both uniformity of hole diameter and inter-hole spacing is critical to producing a well dispersed bubbly flow. The results show that the method of gas injection influences the liquid breakup process. Results are given for steady-flow atomization with low pressure injection into ambient air.
Technical Paper

Experimental and Numerical Studies of High Pressure Multiple Injection Sprays

1996-02-01
960861
Characterization of high pressure diesel sprays has been performed both experimentally and numerically. The experimental study was conducted using a fuel injection system which has a capability of producing multiple injection sprays. The fuel sprays were injected from a multi-hole nozzle into a pressurized cylindrical chamber with optical windows. In order to investigate the effects of a multiple injection strategy on spray characteristics, a double injection spray with the mass evenly distributed between the first and second sprays, and a 1 millisecond dwell between sprays was compared with a single injection spray. Both single and double injection cases had nominally the same injection pressure, injection delivery, and ambient gas density. Transient spray tip penetration lengths and spray angles were obtained from high speed photographic spray images. The spray droplet sizes were derived from the images by using a light extinction method.
Technical Paper

Effects of Mixture Preparation Characteristics on Four-Stroke Utility Engine Emissions and Performance

1996-08-01
961738
A laboratory-based fuel mixture system capable of delivering a range of fuel/air mixtures has been used to observe the effects of differing mixture characteristics on engine combustion through measurement and analysis of incylinder pressure and exhaust emissions. Fuel air mixtures studied can be classified into four different types: 1) Completely homogeneous fuel/air mixtures, where the fuel has been vaporized and mixed with the air prior to entrance into the normal engine induction system, 2) liquid fuel that is atomized and introduced with the air to the normal engine induction system, 3) liquid fuel that is atomized, and partially prevaporized but the air/fuel charge remains stratified up to introduction to the induction system, and 4) the standard fuel metering system. All tests reported here were conducted under wide open throttle conditions. A four-stroke, spark-ignited, single-cylinder, overhead valve-type engine was used for all tests.
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