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A new combustion system with a low compression ratio (CR), specifically oriented towards the exploitment of partially Premixed Charge Compression Ignition (PCCI) diesel engines, has been developed and tested. The work is part of a cooperative research program between Politecnico di Torino (PT) and GM Powertrain Europe (GMPT-E) in the frame of Low Temperature Combustion (LTC) diesel combustion-system design and control. The baseline engine is derived from the GM 2.0L 4-cylinder in-line, 4-valve-per-cylinder EU5 engine. It features a CR of 16.5, a single stage VGT turbocharger and a second generation Common Rail (1600 bar). A newly designed combustion bowl was applied. It features a central dome and a large inlet diameter, in order to maximize the air utilization factor at high load and to tolerate advanced injection timings at partial load. Two different piston prototypes were manufactured by changing the internal volume of the new bowl so as to reach CR targets of 15.5 and 15.

The simulation activity for the piston bowl development in a low compression ratio (CR) high-performance diesel engine is described, starting from the calibration of a 3-D CFD commercial code by pressure-based combustion diagnostics data. Calibration was made for the baseline engine built by GMPT-E, matching experimental pressure traces and heat release rates derived from these through the diagnostic tool. Measured pollutant emissions were also applied for calibration at this stage. The engine was susceptible to modifications, according to the outcomes of combined simulation and experimental investigations. The validated CFD model was used for the screening of three new piston bowls featuring a reduced compression ratio. The 3-D code has been integrated with a robustly calibrated 1-D hydraulic model for the injection system simulation and with a 1-D fluidynamic tool for modeling engine flow processes external to the cylinder to provide quite accurate boundary conditions.

A comparative investigation of both fuel consumption and exhaust emissions has been carried out on a production SI engine operated by either gasoline or compressed natural gas (CNG). The engine had the main features of being a multivalve, fast-burn pent-roof chamber engine with a variable intake-system geometry. It was originally designed at Fiat Auto to operate with unleaded gasoline and was then converted at Politecnico di Torino to run on CNG. To that end, in addition to designing and building the CNG fuel plant, the multipoint Bosch Motronic M1.7 electronic module for injection-duration and spark-timing control was replaced with a Magneti-Marelli IAW ECM designed to obtain a multipoint sequential injection. With this new ECM, the engine was modified so as to work with either natural gas or gasoline.

A numerical model for simulating a Common Rail Piezo Indirect Acting fuel injection-system under steady state as well as transient operating conditions was developed using a commercial code. A 1D flow model of the main hydraulic system components, including the rail, the rail to injector connecting pipe and the injector, was applied in order to predict the influence of the injector layout and of each part of the hydraulic circuit on the injection system performance. The numerical code was validated through the comparison of the numerical results with experimental data obtained on a high performance test bench of the Moehwald-Bosch MEP2000/ CA4000 type. The developed injection-system mathematical model was applied to the analysis of transient flows in the hydraulic circuit paying specific attention to the fluid dynamics internal to the injector.

The variation of turbulent flow quantities with engine speed has been investigated in the combustion chamber of an automotive diesel engine with a high-squish conical-type in-piston bowl and one helicoidal intake duct, at speeds covering the wide range of 600-3000 rpm, under motored conditions. The investigation had the main purpose of studying the engine speed effect on the structure of both cycle-resolved and conventional turbulence over the induction, the compression and the early stage of the expansion stroke. The low frequency component of the fluctuating motion was also investigated.

The burned-gas propagation process has been characterized in two bi-fuel engines by means of a combustion diagnostic tool resulting from the integration of an original multizone heat-release model with a CAD procedure for the burned-gas front geometry simulation. Burned-gas mean expansion speed ub, mean gas speed ug and burning velocity Sb were computed as functions of crank angle and burned-gas radius for a wide range of engine speeds (n = 2000-5500 rpm), loads (bmep = 200-790 kPa), relative air-fuel ratios (RAFR = 0.80-1.60) and spark advances (SA ranging from 8 deg retard to 8 deg advance from MBT), under both gasoline and CNG operations. Finally, the influence of intake runner and combustion chamber geometries on flame propagation process was investigated. Main results show that Sb is generally comparable for the engine running on both gasoline and CNG, at the same engine speed and load, under stoichiometric and MBT operations.

The necessity for further reductions of in-cylinder pollutant formation and the opportunity to minimize engine development and testing times highlight the need of engine thermodynamic cycle simulation tools that are able to accurately predict the effects of fuel, design and operating variables on engine performance. In order to set up reliable codes for indicated cycle simulation in SI engines, an accurate prediction of heat release is required, which, in turn, involves the evaluation of in-cylinder turbulence generation and flame-turbulence interaction. This is generally pursued by the application of a combustion fractal model coupled with semi-empirical correlations of available geometrical and thermodynamical mass-averaged quantities. However, the currently available correlations generally show an unsatisfactory capability to predict the effects of flame-turbulence interaction on burning speed under the overall flame propagation interval.

A production SI engine originally designed at Fiat Auto to operate with unleaded gasoline was converted to run on natural gas. To that end, in addition to designing and building the CNG fuel plant, it was necessary to replace the multipoint electronic module for injection-duration and ignition-timing control with an ECM designed to obtain multipoint sequential injection. The engine was modified so as to work either with gasoline or natural gas. For the present investigation, however, the engine configuration was not optimized for running on methane, in order to compare the performance of the engine operated by the two different fuels with the same compression ratio. In fact, the engine is also interesting as a dual-fuel engine because of its relatively high compression ratio ≈10.5 that is almost suitable for CNG operation. The engine had the main features of being a multivalve, fast-burn pent-roof chamber engine with a variable intake-system geometry.

A contribution has been given to the thermodynamics approach usually used for analyzing the combustion process in IC engines on the basis of cylinder pressure data reduction. A survey of heat release type combustion models and of their calibration methods has first been carried out with specific attention paid to the bulk gas-wall heat transfer correlations used. Experimental results have given evidence that most of these correlations are incapable of predicting the phase shift occurring between the gas-wall temperature difference and the heat transfer during the engine compression and expansion strokes, owing to the transient properties of the fluid directly in contact with the wall. This work develops and applies a refined procedure for heat release analysis of cylinder pressure data including the unsteadiness effects of the convective heat transfer process.

An integrated theoretical and experimental investigation was carried out in order to evaluate the effects that the pump delivery-valve assembly can produce on the performance of a pump-line-nozzle fuel-injection system with a distributor-type pump for automotive diesel engines. Four distinct delivery valves, one constant-pressure valve, one reflux-hole and two relief-volume valves, were separately fitted to the pump and for each configuration of the delivery assembly the system behavior was analyzed under full-load steady-state operations in a wide pump angular-speed range. Fuel injection-rate as well as local pressure time-histories were investigated, paying specific attention to the occurrence and temporal evolution of cavitation phenomena in the pressure pipe and injector nozzle, after the valve closure. The flow across the delivery-valve assembly was theoretically examined in order to ascertain any instability sources as possible causes of cyclic fluctuations.