Measurements and analysis of load and speed effects on the instantaneous wall heat fluxes in a direct injection air‐cooled diesel engine

This work presents an experimental analysis which is carried out to study the instantaneous heat fluxes, during the engine cycle, in the cylinder head and exhaust manifold of a direct injection, air‐cooled, four‐stroke diesel engine. For temperature measurements, a new pre‐amplification unit for fast response thermocouples, appropriate heat flux sensors and an innovative, object‐oriented, control code for fast data acquisition have been designed and developed at the authors' laboratory. The experimental installation separates the engine transient temperature signals into two parts; namely the ‘long’‐ and the ‘short’‐term response ones; followed by their discrete processing in two independent data acquisition systems. One‐dimensional heat conduction with Fourier analysis of the raw temperature data are implemented in order to calculate the instantaneous engine combustion chamber and exhaust pipe heat fluxes. This study concentrates on the correct interpretation of the measured temporal variations of heat fluxes and the examination of the effect of engine load and speed on the cylinder head and exhaust manifold heat flux losses. Many interesting aspects of transient engine heat transfer are revealed. The simultaneous presentation of heat fluxes on the cylinder head and exhaust manifold, together with the engine indicator diagram, sheds light into the mechanisms governing transient heat transfer during an engine cycle. Copyright © 2000 John Wiley & Sons, Ltd.     

活塞环-气缸套润滑摩擦研究

活塞环与气缸套间的润滑、摩擦直接影响到内燃机的动力性、经济性和可靠性。在内燃机实际运行过程中,缸内工作过程循环变动及活塞气缸套间动接触导热直接影响到润滑油膜的状态,因而活塞环在缸套中的不同位置时的摩擦、润滑状态各不相同。在传统的活塞环组稳态热混合润滑的基础上,考虑到活塞组一气缸套动接触系统瞬态传热,建立了活塞环组的非稳态热混合润滑、摩擦数理模型及数值方法。运用该方法可模拟出活塞环组润滑、摩擦特性,并可预测出不同瞬时润滑油膜的温度场、压力分布、油膜厚度、摩擦功和摩擦热等重要参数。     

Comparative first- and second-law parametric study of transient diesel engine operation

A computer model is developed for studying the first- and second-law (availability) balances of a turbocharged diesel engine, operating under transient load conditions. Special attention is paid to the direct comparison between the results from the two laws, for various operating parameters of the engine. The model simulates the transient operation on a degree crank angle basis, using a detailed analysis of mechanical friction, a separate consideration for the processes of each cylinder during a cycle (“multi-cylinder” model) and a mathematical model of the fuel pump. Experimental data taken from a marine duty, turbocharged diesel engine, located at the authors’ laboratory, are used for the evaluation of the model's predictive capabilities. The first-law (e.g., engine speed, fuel pump rack position, engine load, etc.) and second-law (e.g., irreversibilities, heat loss and exhaust gases) terms for the diesel engine cylinder are both computed and depicted in comparison, using detailed diagrams, for various engine operating parameters. It is revealed that, at least for the specific engine type and operation, a thermodynamic, dynamic or design parameter can have a conflicting impact on the engine transient response as regards energy and availability properties, implying that both a first- and second-law optimization is needed for best performance evaluation.     

Effect of oscillatory motion on heat transfer at vertical flat surfaces

The effect of oscillations on heat transfer at vertical surfaces is investigated and a model is developed that predicted both the transient and time average heat transfer rates. The transient behavior of the heat transfer indicates the presence of an oscillatory component superimposed on a larger steady one that does not reach zero during flow reversal. This was explained in terms of the interaction between a “quasi-steady oscillatory” mechanism near the leading edge, and a “pseudo-steady diffusive” far from it. The analysis further revealed that the time average heat transfer rate can be adequately estimated using a mixed “forced-natural” convections correlation, with the forced convection component estimated based on the time average oscillatory Reynolds number Re_v = awL/ν. The agreement between the model predictions and the experimental measurements makes it applicable for predicting heat transfer characteristics and velocity fluctuations near heated vertical surfaces in presence of oscillatory motion. The model is also applicable for predicting heat transfer rates under conditions where oscillatory motion is used to achieve specificity in temperature control without affecting process residence time, such as in biomedical and biochemical applications. The modest heat transfer enhancement (<2) due to oscillatory motion is attributed to the small convective term in the energy equation, which is consistent with previous investigations where increasing the axial temperature gradient in presence of oscillatory motion was shown to achieve much higher heat transfer enhancement.     

Experimental and simulation analysis of the transient operation of a turbocharged multi-cylinder IDI diesel engine

An experimental and theoretical analysis is carried out to study the response of a multi-cylinder, turbocharged, IDI (indirect injection) compression ignition engine, under transient operating conditions. To this aim, a comprehensive digital computer model is developed which solves the governing differential equations individually for each cylinder, providing thus increased accuracy over previous ‘single-cylinder’ simulations. Special attention has been paid for diversifying the transient operation from the steady-state one, providing improved or even new relations concerning combustion, heat transfer to the cylinder walls, friction, turbocharger and aftercooler operation, and dynamic analysis for the transient case. An extended steady state and transient experimental work is conducted on a specially developed engine test bed configuration, located at the authors' laboratory, which is connected to a high-speed data acquisition and processing system. The steady-state measurements are used for the calibration of the individual submodel constants. The transient investigation includes both speed and load changes operating schedules. During each transient test four major measurements are continuously made, i.e. engine speed, fuel pump rack position, main chamber pressure and turbocharger compressor boost pressure. The hydraulic brake coupled to the engine possesses a high mass moment of inertia and long nonlinear load-change times, which together with the indirect injection nature of the engine are important challenges for the simulation code. Explicit multiple diagrams are given to describe the engine and turbocharger transient behaviour including smoke predictions. The agreement between experimental and predicted responses is satisfactory, for all the cases examined, proving the validity of the simulation process, while providing useful information for the engine response under various transient operations. © 1998 John Wiley & Sons, Ltd.     

LES analysis of turbulent flow and heat transfer in motored engines with various SGS models

This paper presents the application of three different subgrid-scale (SGS) models in a large eddy simulation (LES) for investigating the turbulent flow field and wall heat transfer during the compression-expansion strokes in two types of engine configuration under realistic engine conditions. Predictions were compared with experimental measurements (including the local heat flux and swirl velocity), and with those calculated from the conventional K-ε model. The results of the Van Driest wall damping model for LES were found to be in the best agreement with experimental data. The variations of velocity vector plots, isothermal profiles with crank angle were realized in the “Pancake” chamber engine. The variation of squish strength in the cylinder was also investigated by illustrating the friction velocity variations at different radial locations in the “Deep Bowl Piston” engine.     

考虑沸腾和缸内局部传热的缸盖流固耦合传热分析

以某商用车直列6缸柴油机作为研究对象,基于缸内传热模型获得内燃机缸盖和缸套的燃气侧局部传热边界条件;基于均相流沸腾传热模型获得水侧传热边界;实现水侧、燃气侧边界与结构温度场计算的耦合,并判断水腔内沸腾传热的状态。结果表明:缸盖温度计算值与实测值吻合,缸盖最高温度位于缸盖底面两个排气门之间;排气门之间的燃气传热系数和燃气温度均处于较高值,缸内局部传热显著;在缸盖底面中心和排气门附近水腔内的冷却水处于部分发展泡核沸腾状态。     

Experimental evaluation of local instantaneous heat transfer characteristics in the combustion chamber of air-cooled direct injection diesel engine

An experimental analysis is conducted investigating the differences between the variations of overall and local instantaneous heat transfer coefficients, during the engine cycle, in the combustion chamber walls of a direct injection (DI), air-cooled diesel engine located at the authors’ laboratory. For this purpose, a novel experimental installation is developed, which separates the engine transient temperature signals into two parts, namely the long- and the short-term response ones, processed in two independent data acquisition systems. Moreover, a new pre-amplification unit for fast response thermocouples, appropriate heat flux sensors and an object-oriented control code for fast data acquisition have been designed and applied. Experimentally obtained cylinder pressure diagrams are used as a basis for the calculation of the overall heat transfer coefficients, whereas one-dimensional heat conduction theory with Fourier analysis techniques, combined with an iterative procedure between calculated and measured temperature data, are implemented in order to calculate the instantaneous local heat transfer coefficients in the engine cylinder. Analysis of the experimental results reveals interesting aspects of transient engine heat transfer. Significant differences are disclosed between the overall and local heat transfer coefficient variations, with the importance of the latter one on engine design being emphasized. The local heat transfer coefficient on the cylinder head is quantified based on the experimental data. The effect of engine speed and load as well as of the air swirling motion on the heat transfer variations are presented. From the analysis results it is concluded that the instantaneous heat transfer variation is non-uniform, unlike its values calculated from standard correlations that assume spatial uniformity, noting that such information, especially for air-cooled diesel engines, seems to be very scarce in the open literature.     

Analysis of local convective heat transfer in a spark ignition engine

A computational fluid dynamics (CFD) code is applied to simulate fluid flow, heat transfer and combustion in a four-stroke single cylinder engine with pent roof combustion chamber geometry, having two inlet valves and two exhaust valves. Heat flux and heat transfer coefficient on the cylinder head, cylinder wall, piston, intake and exhaust valves are determined with respect to crank angle position. Results for a certain condition are compared for total heat transfer coefficient of the cylinder engine with available correlation proposed by experimental measurement in the literature and close agreement are observed. It was found that the local value of heat transfer coefficient varies considerably in different parts of the cylinder, but they have equivalent trend with crank angle. Based on the results, new correlations are suggested to predict maximum and minimum convective heat transfer coefficient in the combustion chamber of a SI engine.     

Study of the steady and transient temperature field and heat flow in the combustion chamber components of a medium speed diesel engine using finite element analyses

The present work describes the development of a model for the calculation of the temperature field and heat flow in the combustion chamber components of internal combustion piston engines, which occur both under steady and transient engine operating conditions. Two and three-dimensional finite-element analyses were implemented for the representation of the complex geometry metal components (piston, liner and cylinder head). The model is applied for the piston and liner of a medium speed diesel engine, for which relevant experimental data exist in the literature. Special care is given for accurately specifying the thermal boundary conditions (temperatures and heat transfer coefficients). Gas side boundary conditions are calculated using a thermodynamic cycle simulation code, including spatial variation of the gas side heat transfer coefficient. Coolant sides (water on the external liner surface and oil on the piston undercrown surface) boundary conditions are calculated using correlations pertaining to real engine conditions. Also an effort is made to model the piston-ring belt-liner complex thermal paths using equivalent thermal circuits. A satisfactory degree of agreement is found between theoretical predictions and experimental measurements, revealing that the finite-element methods presented are successful in formulating this kind of problem, giving accurate results with reasonable computational cost. The utilization of the model reveals very clearly the essential role of engine operating transients (sudden changes in speed and/or load) in the generation of sharp temperature excursions in the metal components until a new steady state is reached. The phenomenon should be taken into account for correct engine design and safe operation (i.e. the avoidance of high local stresses).     

带有进排气旁通的相继增压柴油机的计算分析

建立了带有进排气旁通的相继增压柴油机稳态仿真程序,缸内过程采用充满与排空法,进排气过程采用一维非定常流动模型,选择有限体积法对其进行离散求解。对某船用带有进排气旁通的相继增压柴油机,进行了多组性能模拟计算,结果表明:计算结果与试验数据基本一致;柴油机转速在855～920 r/min时,开启旁通阀,能增加压气机的空气流量,避免喘振,并提高了增压压力,降低了排温,改善了柴油机的大扭矩性能,但柴油机的经济性有少量降低。     

Second-law analyses applied to internal combustion engines operation

This paper surveys the publications available in the literature concerning the application of the second-law of thermodynamics to internal combustion engines. The availability (exergy) balance equations of the engine cylinder and subsystems are reviewed in detail providing also relations concerning the definition of state properties, chemical availability, flow and fuel availability, and dead state. Special attention is given to identification and quantification of second-law efficiencies and the irreversibilities of various processes and subsystems. The latter being particularly important since they are not identified in traditional first-law analysis. In identifying these processes and subsystems, the main differences between second- and first-law analyses are also highlighted. A detailed reference is made to the findings of various researchers in the field over the last 40 years concerning all types of internal combustion engines, i.e. spark ignition, compression ignition (direct or indirect injection), turbocharged or naturally aspirated, during steady-state and transient operation. All of the subsystems (compressor, aftercooler, inlet manifold, cylinder, exhaust manifold, turbine), are also covered. Explicit comparative diagrams, as well as tabulation of typical energy and exergy balances, are presented. The survey extends to the various parametric studies conducted, including among other aspects the very interesting cases of low heat rejection engines, the use of alternative fuels and transient operation. Thus, the main differences between the results of second- and first-law analyses are highlighted and discussed.     

Experimental investigation of the Exhaust Gas Recirculation effects on irreversibility and Brake Specific Fuel Consumption of indirect injection diesel engines

An experimental study was carried out to investigate the effect of using Exhaust Gas Recirculation (EGR) on various exergy terms of an IDI diesel engine cylinder. In this paper also the effectiveness of total in-cylinder irreversibility on Brake Specific Fuel Consumption (BSFC) in a diesel engine is investigated. To serve this aim an exergy analysis is conducted on the engine cylinder which provides all the availability terms by which the evaluation of in-cylinder irreversibilities is possible. The availability terms including heat transfer, inlet and exhaust gases and work output are presented during the engine operation at different load and speeds. To clarify the effect of using EGR in each case, EGR is introduced to the cylinder at various ratios during the tests. Finally, the dependence of total in-cylinder irreversibility and engine BSFC at particular engine operating conditions is introduced and the variations are compared. The results show that using EGR mostly increases the total in-cylinder irreversibility mainly due to extension of the flame region which reduces maximum combustion temperature. Also, the results revealed that the variations of the total in-cylinder irreversibility and engine BSFC follow the same trend especially at high load conditions.     

发动机冷却系统流固耦合稳态传热三维数值仿真

为解决发动机传热计算时冷却水与缸套、机体之间的流动与传热耦合边界问题，建立了发动机活塞组-缸套-冷却水-机体三维流固耦合系统，并利用有限元分析软件的流固耦合计算功能，把单个零件的传热外边界条件处理成内边界，使得传热仿真更合理更简单。以某增压柴油机为例，用有限元分析软件ANSYS对建立的三维流固耦合模型进行了稳态传热数值仿真，得到了耦合系统的温度场和流场云图。与标定工况下活塞和缸套的温度场测量数据进行了对比分析，结果表明：仿真结果与实测数据吻合较好，误差控制在8％以内。由此说明应用流固耦合仿真方法可以较好地模拟发动机稳态传热。     

Experimental investigation on effect of misfire and postfire on backfire in a hydrogen fuelled automotive spark ignition engine

This study investigates the effect of misfire and postfire on backfire in a hydrogen-fuelled automotive spark ignition engine. Backfire is a preignition phenomenon and the flame propagates toward the engine's intake manifold during the suction stroke. Postfire is a post-ignition phenomenon occurring in the exhaust manifold during the exhaust stroke and the flame propagates towards the exhaust manifold or backflow to the combustion chamber or combined both. Misfire occurs when cranking the engine (starting), fouled spark plug, and unoptimized spark timing. Several misfire cycles lead to an increase in the accumulation of unburnt hydrogen-air charge inside the cylinder and 13% hydrogen leaves the exhaust manifold resulting in postfire occurrence in a subsequent cycle. The postfire in the current cycle acting as an external ignition source for the preignition of the accumulated hydrogen-air charge results in backfire in the immediate next cycle. The misfire, postfire and backfire stall the engine operation due to a drop in indicated mean effective pressure. The experimental data indicates the backfire limiting equivalence ratio (BLER) should decrease with an increase in the engine speed as the equivalence ratio varies from 0.91 at 2000 rpm to 0.4 at 4900 rpm. As too advancement of spark timing increases the probability of misfire leading to postfire and backfire, the engine must be operated at backfire limiting spark timing to avoid misfire, postfire, and backfire occurrence. An important point emerged from this study that misfire without postfire does not lead to backfire occurrence. Physical mechanisms and mitigative measures for misfire, postfire and backfire are discussed in detail.     

基于双向流固耦合的汽油机排气歧管热应力分析

联合AVL-Fire与ABAQUS软件,对一台汽油机排气歧管进行温度场、热应力分析.首先利用AVL-Fire对排气歧管做内外流场CFD分析,得到排气歧管内外表面的热边界条件,即流体温度及换热系数;然后把热边界条件映射到有限元面单元,并通过有限元技术与排气歧管实体单元相耦合,通过ABAQUS算出排气歧管温度场,并把壁面温度场返回作为下一轮CFD计算的边界条件,再重复前一轮计算.如此反复,直至符合精度要求,最后计算热应力.     

Investigation of the temperature oscillations in the cylinder walls of a diesel engine with special reference to the limited cooled case

This work investigates the interesting phenomenon of the temperature (cyclic) oscillations in the combustion chamber walls of a diesel engine. For this purpose, a comprehensive simulation code of the thermodynamic cycle of the engine is developed taking into account both the closed and the open parts of it. The energy and state equations are applied, with appropriate combustion, gas heat transfer, and mass exchange with the atmosphere sub‐models, to yield cylinder pressure, local temperatures and heat release histories as well as various performance parameters of the engine. The model is appropriately coupled to a wall periodic conduction model, which uses the gas temperature variation as boundary condition throughout the engine cycle after being treated by Fourier analysis techniques. It is calibrated against measurements, at various load and speed conditions, from an experimental work carried out on a direct injection (DI), naturally aspirated, four‐stroke, diesel engine located at the authors' laboratory, which has been reported in detail previously. After gaining confidence into the predictive capabilities of the model, it is used to investigate the phenomenon further, thus providing insight into many interesting aspects of transient engine heat transfer, as far as the influence that engine wall material properties have on the values of cyclic temperature swings. These swings can take prohibitive values causing high wall thermal fatigue, when materials of specific technological interest such as thermal insulators (ceramics) are used, and may lead to deterioration in engine performance. Copyright © 2004 John Wiley & Sons, Ltd.     

Heat transfer measurement techniques of film cooling in gas turbine blades

An overview of the experimental techniques employed or developed for the measurement of local and mean heat transfer coefficients and adiabatic wall effectiveness from film cooled surfaces is presented. The scope of this work is confined to heat transfer techniques applied to film cooling of gas turbine blades, steady state and transient. The latter technique have significant advantages over the former in that it yields results at parameters duplicating those at the full-scale operating engine conditions, although the former technique offers simplicity.     

Transient natural convection heat transfer of liquid D-mannitol on a horizontal cylinder

Transient and steady state natural convection heat transfer for D-mannitol on a horizontal cylinder was investigated experimentally at various liquid temperatures and heat input conditions. To clarify the natural convection phenomena of D-mannitol, transient and steady heat transfer coefficients were measured under various liquid temperatures of D-mannitol and periods of heat generation rates from a horizontal platinum cylinder. The platinum cylinder with a diameter of 1 mm and a length of 43.5 mm was used as the test heater in this experiment. Experimental results indicated that the steady heat transfer coefficient of D-mannitol was affected by the liquid temperature. As the liquid temperature increased, it was understood that the effect of liquid temperature weakened. When the period of the heat generation rate was changed, the heat transfer process was divided into natural convection heat transfer and conductive heat transfer. It was considered that the conductive heat transfer was more dominant as the period of the heat generation rate decreased. The empirical correlations of steady and transient heat transfer coefficients for D-mannitol were obtained.     

Modeling and dynamic control simulation of unitary gas engine heat pump

Based on the dynamic model of the gas engine heat pump (GEHP) system, an intelligent control simulation is presented to research the dynamic characteristics of the system in the heating operation. The GEHP system simulation model consists of eight models for its components including a natural gas engine, a compressor, a condenser, an expansion valve, an evaporator, a cylinder jacket heat exchanger, an exhaust gas heat exchanger and an auxiliary heater. The intelligent control model is composed of the prediction controller model and the combined controller model. The Runge–Kutta Fehlberg fourth–fifth order algorithms are used to solve the differential equations. The results show that the model is very effective in analyzing the effects of the control system, and the steady state accuracy of the intelligent control scheme is higher than that of the fuzzy controller.