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In this work a detailed model to simulate the transient behavior of catalytic converters is presented. The model is able to predict the unsteady and reacting flows in the exhaust ducts, by solving the system of conservation equations of mass, momentum, energy and transport of reacting chemical species. The en-gine and the intake system have not been included in the simulation, imposing the measured values of mass flow, gas temperature and chemical composition as a boundary condition at the inlet of the exhaust system. A detailed analysis of the diffusion stage triggering is proposed along with simplifications of the physics, finalized to the reduction of the calculation time. Submodels for water condensation and its following evaporation on the monolith surface have been taken into account as well as oxygen storage promoted by ceria oxides.

A numerical investigation on a series of Diesel spray experiments in constant-volume vessels is proposed. Non reacting conditions were used to assess the spray models and to determine the grid size required to correctly predict the fuel-air mixture formation process. To this end, not only computed liquid and vapor penetrations were compared with experimental data, but also a detailed comparison between computed and experimental mixture fraction distributions was performed at different distances from the injector. Grid dependency was reduced by introducing an Adaptive Local Mesh Refinement technique (ALMR) with an arbitrary level of refinement. Once the capabilities of the current implemented spray models have been assessed, reacting conditions at different ambient densities and temperatures were considered. A Perfectly Stirred Reactor (PSR) combustion model, based on a direct integration of complex chemistry mechanisms over a homogenous cell, was adopted.

Detailed chemistry and turbulence-chemistry interaction need to be properly taken into account for a realistic combustion simulation of IC engines where advanced combustion modes, multiple injections and stratified combustion involve a wide range of combustion regimes and require a proper description of several phenomena such as auto-ignition, flame stabilization, diffusive combustion and lean premixed flame propagation. To this end, different approaches are applied and the most used ones rely on the well-stirred reactor or flamelet assumption. However, well-mixed models do not describe correctly flame structure, while unsteady flamelet models cannot easily predict premixed flame propagation and triple flames. A possible alternative for them is represented by transported probability density functions (PDF) methods, which have been applied widely and effectively for modeling turbulent reacting flows under a wide range of combustion regimes.

A new multi-zone model for the simulation of HCCI engine is here presented. The model includes laminar and turbulent diffusion and conduction exchange between the zones and the last improvements on the numerical aspects. Furthermore, a new strategy for the zone discretization is presented, which allows a better description of the near-wall zones. The aim of the work is to provide a fast and reliable model for carrying out chemical analysis with detailed kinetic schemes. A preliminary sensitivity analysis allows to verify that 10 zones are a convenient number for a good compromise between the computational effort and the description accuracy. The multi-zone predictions are then compared with the CFD ones to find the effective turbulence parameters, with the aim to describe the near-wall phenomena, both in a reactive and non-reactive cases.

In this work a multilevel CFD analysis have been applied for the design of an intake air-box with improved characteristics of noise reduction and fluid dynamic response. The approaches developed and applied for the optimization process range from the 1D to fully 3D CFD simulation, exploring hybrid approaches based on the integration of a 1D model with quasi-3D and 3D tools. In particular, the quasi-3D strategy is exploited to investigate several configurations, tailoring the best trade-off between noise abatement at frequencies below 1000 Hz and optimization of engine performances. Once the best configuration has been defined, the 1D-3D approach has been adopted to confirm the prediction carried out by means of the simplified approach, studying also the impact of the new configuration on the engine performances.

Swirling flows are very dominant in applied technical problems, especially in IC engines, and their prediction requires rather sophisticated modeling. An adaptive low-pass filtering procedure for the modeled turbulent length and time scales is derived and applied to Menter' original k - ω SST turbulence model. The modeled length and time scales are compared to what can potentially be resolved by the computational grid and time step. If the modeled scales are larger than the resolvable scales, the resolvable scales will replace the modeled scales in the formulation of the eddy viscosity; therefore, the filtering technique helps the turbulence model to adapt in accordance with the mesh resolution and the scales to capture.

In recent years, the increase of gasoline fuel injection pressure is a way to improve thermal efficiency and lower engine-out emissions in GDI homogenous combustion concept. The challenge of controlling particulate formation as well in mass and number concentrations imposed by emissions regulations can be pursued improving the mixture preparation process and avoiding mixture inhomogeneity with ultra-high injection pressure values up to 100 MPa. The increase of the fuel injection pressure in GDI homogeneous systems meets the demand for increased injector static flow, while simultaneously improves the spray atomization and mixing characteristics with consequent better combustion performance. Few studies quantify the effects of high injection pressure on transient gasoline spray evolution. The aim of this work was to simulate with OpenFOAM the spray morphology of a commercial gasoline injected in a constant volume vessel by a prototypal GDI injector.

A wheel able to measure the generalized forces at the hub of a race motorcycle has been developed and used. The wheel has a very limited mass. It is made from magnesium with a special structure to sense the forces and provide the required level of stiffness. The wheel has been tested both indoor for preliminary approval and on the track. The three forces and the three moments acting at the hub can be measured with a resolution of 1N and 0.3Nm respectively. A specifically programmed DSP (Digital Signal Processor) embedded in the sensor allows real-time acquisition and processing of the six signals of forces/torques components. The signals are sent via Bluetooth to an onboard receiver connected to the vehicle CAN (Controller Area Network) bus. Each signal is sampled at 200Hz. The wheel can be used to derive the actual tyre characteristics or to record the loads acting at the hub.

The modeling of fuel sprays under well-characterized conditions relevant for heavy-duty Diesel engine applications, allows for detailed analyses of individual phenomena aimed at improving emission formation and fuel consumption. However, the complexity of a reacting fuel spray under heavy-duty conditions currently prohibits direct simulation. Using a systematic approach, we extrapolate available spray models to the desired conditions without inclusion of chemical reactions. For validation, experimental techniques are utilized to characterize inert sprays of n-dodecane in a high-pressure, high-temperature (900 K) constant volume vessel with full optical access. The liquid fuel spray is studied using high-speed diffused back-illumination for conditions with different densities (22.8 and 40 kg/m3) and injection pressures (150, 80 and 160 MPa), using a 0.205-mm orifice diameter nozzle.

Metallic foams or sponges are materials with a cell structure suitable for many industrial applications, such as reformers, heat catalytic converters, etc. The success of these materials is due to the combination of various characteristics such as mechanical strength, low density, high specific surface, good thermal exchange properties, low flow resistance and sound absorption. Different materials and manufacturing processes produce different type of structure and properties for various applications. In this work a genetic algorithm has been developed and applied to support the design of catalytic devices. In particular, two substrates were considered, namely the traditional honeycomb and an alternative open-cell foam type. CFD simulations of pressure losses and literature based correlations for the heat and mass transfer were used to support the genetic algorithm in finding the best compromise between flow resistance and pollutant abatement.

The interaction of turbulent premixed methane combustion with the surrounding flow field can be studied using optically accessible test rigs such as a rapid compression expansion machine (RCEM). The high flexibility offered by such a test rig allows its operation at various thermochemical conditions at ignition. However, limitations inherent to such test rigs due to the absence of an intake stroke do not allow turbulence production as found in IC-engines. Hence, means to introduce turbulence need to be implemented and the relevant turbulence quantities have to be identified in order to enable comparability with engine relevant conditions. A dedicated high-pressure direct injection of air at the beginning of the compression phase is considered as a measure to generate adjustable turbulence intensities at spark timing and during the early flame propagation.

The paper deals with the design and manufacturing of a McPherson suspension arm made from short glass fiber reinforced polyamide (PA66). The design of the arm and the design of the molds have been made jointly. According to Industry 4.0 paradigms, a full digitalization of both the product and process has been performed. Since the mechanical behavior of the suspension arm strongly depends on constraints which are difficult to be modelled, a simpler structure with well-defined mechanical constraints has been developed. By means of such simple structure, the model for the behavior of the material has been validated. Since the suspension arm is a hybrid structure, the associated simple structure is hybrid as well, featuring a metal sheet with over-molded polymer. The issues referring to material flow, material to material contact, weld lines, fatigue strength, high and low temperature behavior, creep, dynamic strength have been investigated on the simple structure.

Nowadays a great attention is paid to the level and quality of noise radiated from the tailpipe end of intake and exhaust systems, to control the gas dynamic noise emitted by the engine as well as the characteristics of the cabin interior sound. The muffler geometry can be optimized consequently, to attenuate or remark certain spectral components of the engine noise, according to the result expected. Evidently the design of complex silencing systems is a time-consuming operation, which must be carried out by means of concurrent experimental measurements and numerical simulations. In particular, 1D and multiD linear/non-linear simulation codes can be applied to predict the silencer behavior in the time and frequency domain. This paper describes the development of a 1D-multiD integrated approach for the simulation of complex muffler configurations such as reverse chambers with inlet and outlet pipe extensions and perforated silencers with the addition of sound absorbing material.

Today, Direct-Injection systems are widely used on Spark-Ignition engines in combination with turbo-charging to reduce the fuel-consumption and the knock risks. In particular, the spread of Gasoline Direct Injection (GDI) systems is mainly related to the use of new generations of multi-hole, high-pressure injectors whose characteristics are quite different with respect to the hollow-cone, low-pressure injectors adopted in the last decade. This paper presents the results of an experimental campaign conducted on the spray produced by a GDI six-holes injector into a constant volume vessel with optical access. The vessel was filled with air at atmospheric pressure. Different operating conditions were considered for an injection pressure ranging from 3 to 20 MPa. For each operating condition, spray images were acquired by a CCD camera and then post processed to evaluate the spray penetration and cone angles.

Many studies have been carried out to optimize the aerodynamic performances of a single car or a single vehicle. In present days the traffic increases and sophisticated technologies are developing to guarantee the drivers safety, to minimize the fuel consumption and be more environmentally friendly. Within this research area a new technique that is being studied is Platooning: this means that different vehicles travel in a configuration that minimizes the aerodynamic drag and therefore the fuel consumption and the longitudinal space. In the present study platoons with different vehicles and configurations are taken into account, to analyze the influence of car shape and relative distance between the vehicles. The research has been carried out using CFD techniques to investigate the different flow fields around different platoons, while wind tunnel tests have been used to validate the results of the CFD simulations.

In the paper, a procedure to assess the quality of the shielding effect of wind barriers to protect large sided vehicles crossing the wake of a bridge pylon under cross wind conditions is proposed. The methodology is based on Multi-Body simulations of the response of the vehicle-driver system when it is subjected to the sudden change of the aerodynamic forces due to the wind-tower interaction. The aerodynamic forces that are instantaneously acting on the vehicle are computed according to a force distribution approach that relies on wind tunnel tests that may be performed on still scaled models. From the knowledge of the aerodynamic force distribution along the vehicle at different yaw angles and of the mean wind profile across the tower wake, the aerodynamic force, acting on the moving vehicle, is reconstructed at each time step taking into consideration the actual vehicle-driver dynamics.

Modeling plume interaction and collapse for direct-injection gasoline sprays is important because of its impact on fuel-air mixing and engine performance. Nevertheless, the aerodynamic interaction between plumes and the complicated two-phase coupling of the evaporating spray has shown to be notoriously difficult to predict. With the availability of high-speed (100 kHz) Particle Image Velocimetry (PIV) experimental data, we compare velocity field predictions between plumes to observe the full temporal evolution leading up to plume merging and complete spray collapse. The target “Spray G” operating conditions of the Engine Combustion Network (ECN) is the focus of the work, including parametric variations in ambient gas temperature. We apply both LES and RANS spray models in different CFD platforms, outlining features of the spray that are most critical to model in order to predict the correct aerodynamics and fuel-air mixing.

The flow field resulting from injecting a gas jet into a crossflow confined in a narrow square duct has been studied under steady regime using schlieren imaging and laser Doppler velocimetry (LDV). This transparent duct is intended to simulate the intake port of an internal combustion engine fueled by gaseous mixture, and the jet is issued from a round nozzle. The schlieren images show that the relative small size of the duct would confine the development of the transverse jet, and the interaction among jet and sidewalls strongly influences the mixing process between jet and crossflow. The mean velocity and turbulence fields have been studied in detail through LDV measurements, at both center plane and several cross sections. The well-known flow feature formed by a counter rotating vortex pair (CVP) has been observed, which starts to appear at the jet exit section and persists far downstream contributing to enhancing mixing process.

In recent years, concerns for environmental pollution and oil price stimulated the demand for vehicles based on technologies alternative to traditional IC engines. Nowadays several carmakers include hybrid vehicles among their offer and first full electric vehicles appear on the market. Among the different layout of the electric power-train, four in-wheel motors appear to be one of the most attractive. Besides increasing the inner room, this architecture offers the interesting opportunity of easily and efficiently distribute the driving/braking torque on the four wheels. This characteristic can be exploited to generate a yaw moment (torque vectoring) able to increase lateral stability and to improve the handling of a vehicle. The present paper presents and compares two different torque vectoring control strategies for an electric vehicle with four in-wheel motors. Performances of the control strategies are evaluated by means of numerical simulations of open and closed loop maneuvers.

This paper is focused on the development and application of a CFD methodology that can be applied to predict the fuel-air mixing process in stratified charge, sparkignition engines. The Eulerian-Lagrangian approach was used to model the spray evolution together with a liquid film model that properly takes into account its effects on the fuel-air mixing process into account. However, numerical simulation of stratified combustion in SI engines is a very challenging task for CFD modeling, due to the complex interaction of different physical phenomena involving turbulent, reacting and multiphase flows evolving inside a moving geometry. Hence, for a proper assessment of the different sub-models involved a detailed set of experimental optical data is required. To this end, a large experimental database was built by the authors.