Edward Hopkins

A novel calibration methodology is presented to accurately predict the fundamental characteristics of high-pressure fuel sprays for Gasoline Direct Injection (GDI) applications. The model was developed within the Siemens Simcenter STARCD 3D CFD software environment and used the Lagrangian–Eulerian solution scheme. The simulations were carried out based on a quiescent, constant volume, computational vessel to reproduce the real spray testing environment. A combination of statistic and optimisation methods was used for spray model selection and calibration and the process was supported by a wide range of experimental data. A comparative study was conducted between the two most commonly used models for fuel atomisation: Kelvin–Helmholtz/Rayleigh–Taylor (KH–RT) and Reitz–Diwakar (RD) break-up models. The Rosin–Rammler (RR) mono-modal droplet size distribution was tuned to assign initial spray characteristics at the critical nozzle exit location. A half factorial design was used to reveal how the various model calibration factors influence the spray properties, leading to the selection of the dominant ones. Numerical simulations of the injection process were carried out based on space-filling Design of Experiment (DoE) schedules, which used the dominant factors as input variables. Statistical regression and nested optimisation procedures were then applied to define the optimal levels of the model calibration factors. The method aims to give an alternative to the widely used trial-and-error approach and unveils the correlation between calibration factors and spray characteristics. The results show the importance of the initial droplet size distribution and secondary break-up coefficients to accurately calibrate the entire spray process. RD outperformed KH–RT in terms of prediction when comparing numerical spray tip penetration and droplet size characteristics to the experimental counterparts. The calibrated spray model was able to correctly predict the spray properties over a wide range of injection pressure. The work presented in this paper is part of the APC6 DYNAMO project led by Ford Motor Company.

This paper presents the details of a Computational Fluid Dynamics methodology to accurately model the process of mixture preparation in modern Gasoline Direct Injection engines, with particular emphasis on liquid film as one of the main causes of Particulate Matter formation. The proposed modelling protocol, centred on the Bai-Onera approach of droplets-wall interaction and on multi-component surrogate fuel blend models, is validated against relevant published data and then applied to a modern small-capacity GDI engine, featuring centrally-mounted spray-guided injection system. The work covers a range of part-load, stoichiometric and theoretically-homogeneous operating conditions, for which experimental engine data and engine-out Particle Number measurements were available. The results, based on the parametric variation of start of injection timing and injection pressure, demonstrate how both fuel mal-distribution and liquid film retained at spark timing, may contribute to PN emissions, whilst their relative importance vary depending on operating conditions and engine control strategy. Control of PN emissions and compliance with future, more stringent regulations remain large challenges for the engine industry. Renewed and disruptive approaches, which also consider the sustainability of the sector, appear to be essential. This work, developed using Siemens Simcenter CFD software as part of the Ford-led APC6 DYNAMO project, aims to contribute to the development of a reliable and cost-effective digital toolset, which supports engine development and diagnostics through a more fundamental assessment of engine operation and emissions formation.

Transpired Solar Collectors (TSCs) are simple low maintenance air heating systems which have been widely used for agricultural and industrial applications. In spite of their potential, these systems have not been yet widely employed in residential buildings as they are unable to generate high grade heat for moderate and low ventilation demands. Hence there is an opportunity for optimisation studies in order to enhance the thermal performance of these systems.

Optimisation and parametric studies can be costly and time consuming if carried out by physical experiments. CFD models however offer a more flexible and less expensive tool to carry out such studies. This research has aimed to optimise the geometry of the solar absorber plate using a validated CFD model which accounts for a wide range of the key factors affecting TSC performance.

A 2nd order polynomial predictive model was developed based on the CFD results with Root Mean Squared Error (RMSE) of 3.8%. The predictive model was used to identify an optimal geometry which delivers a Heat Exchange Effectiveness (HEE) of 0.739. The optimised geometry demonstrated 43% increase in HEE whilst using 28% less material compared to the baseline geometry under the same operating conditions. This geometry can be integrated with other performance enhancement techniques to further improve the thermal performance of TSCs.