David Thornhill

Experimental Investigation into the Free Air-Cooling of Air-Cooled Cylinders

This paper describes an experimental investigation into the surface heat transfer coefficient of finned metal cylinders in a free air stream. Eight cast aluminium alloy cylinders were tested with four different fin pitches and five different fin lengths. The cylinders and their fins were designed to be representative of those found on a motorcycle engine. Each electrically heated cylinder was mounted in a wind tunnel and subjected to a range of air speeds between 2 and 20 m/s. The surface heat transfer coefficient, h, was found primarily to be a function of the air speed and the fin separation, with fin length having a lesser effect. The coefficient increases with airspeed and as the fins are separated or shortened. It was also noted that a limiting value of coefficient exists, influenced only by airspeed. Above the limiting value the surface heat transfer could not be increased by further separation of the fins or reduction in their length.

The technical merits of turbogenerating shown through the design, validation and implementation of a one-dimensional engine model

Turbocompounding is the process of recovering a proportion of an engine’s fuel energy that would otherwise be lost in the exhaust process and adding it to the output power. This was first seen in the 1930s and is carried out by coupling an exhaust gas turbine to the crankshaft of a reciprocating engine. It has since been recognised that coupling the power turbine to an electrical generator instead of the crankshaft has the potential to reduce the fuel consumption further with the added flexibility of being able to decide how this recovered energy is used. The electricity generated can be used in automotive applications to assist the crankshaft using a flywheel motor generator or to power ancillaries that would otherwise have run off the crankshaft. In the case of stationary power plants, it can assist the electrical power output. Decoupling the power turbine from the crankshaft and coupling it to a generator allows the power electronics to control the turbine speed independently in order to optimise the specific fuel consumption for different engine operating conditions. This method of energy recapture is termed ‘turbogenerating’. This paper gives a brief history of turbocompounding and its thermodynamic merits. It then moves on to give an account of the validation of a turbogenerated engine model. The model is then used to investigate what needs to be done to an engine when a turbogenerator is installed. The engine being modelled is used for stationary power generation and is fuelled by an induced biogas with a small portion of palm oil being injected into the cylinder to initiate combustion by compression ignition. From these investigations, optimum settings were found that result in a 10.90% improvement in overall efficiency. These savings relate to the same engine without a turbogenerator installed operating with fixed fuelling.

Modelling of Unsteady Gas-Dynamic Flow in a Pipe and at Its Exit using CFD

Abstract Traditionally the simulation of the thermodynamic aspects of the internal combustion engine has been undertaken using one-dimensional gas-dynamic models to represent the intake and exhaust systems. Computational fluid dynamics (CFD) analysis of engines has been restricted to modelling of in-cylinder flow structures. With the increasing accessibility of CFD software it is now worth considering its use for complete gas-dynamic engine simulation. This paper appraises the accuracy of various CFD models in comparison with a one-dimensional gas-dynamic simulation. All of the models are compared to experimental data acquired on an apparatus that generates a single gas-dynamic pressure wave. The progress of the wave along a constant area pipe and its subsequent reflection from the open pipe end are recorded with a number of high-speed pressure transducers. It was found that there was little to choose between the accuracy of the one-dimensional model and the best CFD model. The CFD model did not require experimentally derived loss coefficients to represent accurately the open pipe end; however, it took several hundred times longer to complete its analysis. The best congruency between the CFD models and the experimental data was achieved using the RNG k-∊ turbulence model. The open end of the pipe was most effectively represented by surrounding it with a relatively small volume of cells connected to the rest of the environment using a pressure boundary.

An Experimental Assessment of the Effects of Stator Vane Tip Clearance Location and Back Swept Blading on an Automotive Variable Geometry Turbocharger

Off-design performance is of key importance now in the design of automotive turbocharger turbines. Due to automotive drive cycles, a turbine that can extract more energy at high pressure ratios and lower rotational speeds is desirable. Typically a radial turbine provides peak efficiency at U/C values of 0.7, but at high pressure ratios and low rotational speeds, the U/C value will be low and the rotor will experience high values of positive incidence at the inlet. The positive incidence causes high blade loading resulting in additional tip leakage flow in the rotor as well as flow separation on the suction surface of the blade. An experimental assessment has been performed on a scaled automotive VGS (variable geometry system). Three different stator vane positions have been analyzed: minimum, 25%, and maximum flow position. The first tests were to establish whether positioning the endwall clearance on the hub or shroud side of the stator vanes produced a different impact on turbine efficiency. Following this, a back swept rotor was tested to establish the potential gains to be achieved during off-design operation. A single passage CFD model of the test rig was developed and used to provide information on the flow features affecting performance in both the stator vanes and turbine. It was seen that off-design performance was improved by implementing clearance on the hub side of the stator vanes rather than on the shroud side. Through CFD analysis and tests, it was seen that two leakage vortices form, one at the leading edge and one after the spindle of the stator vane. The vortices affect the flow angle at the inlet to the rotor, in the hub region. The flow angle is shifted to more negative values of incidence, which is beneficial at the off-design conditions but detrimental at the design point. The back swept rotor was tested with the hub side stator vane clearance configuration. The efficiency and MFR were increased at the minimum and 25% stator vane position. At the design point, the efficiency and MFR were decreased. The CFD investigation showed that the incidence angle was improved at the off-design conditions for the back swept rotor. This reduction in the positive incidence angle, along with the improvement caused by the stator vane tip leakage flow, reduced flow separation on the suction surface of the rotor. At the design point, both the tip leakage flow of the stator vanes and the back swept blade angle caused flow separation on the pressure surface of the rotor. This resulted in additional blockage at the throat of the rotor reducing MFR and efficiency.

Investigations Into the Performance of a Turbogenerated Biogas Engine During Speed Transients

Turbogenerating is a form of turbocompounding whereby a Turbogenerator is placed in the exhaust stream of an internal combustion engine. The Turbogenerator converts a portion of the expelled energy in the exhaust gas into electricity which can then be used to supplement the crankshaft power. Previous investigations have shown how the addition of a Turbogenerator can increase the system efficiency by up to 9%. However, these investigations pertain to the engine system operating at one fixed engine speed. The purpose of this paper is to investigate how the system and in particular the Turbogenerator operate during engine speed transients. On turbocharged engines, turbocharger lag is an issue. With the addition of a Turbogenerator, these issues can be somewhat alleviated. This is done by altering the speed at which the Turbogenerator operates during the engine’s speed transient. During the transients, the Turbogenerator can be thought to act in a similar manner to a variable geometry turbine where its speed can cause a change in the turbocharger turbine’s pressure ratio. This paper shows that by adding a Turbogenerator to a turbocharged engine the transient performance can be enhanced. This enhancement is shown by comparing the turbogenerated engine to a similar turbocharged engine. When comparing the two engines, it can be seen that the addition of a Turbogenerator can reduce the time taken to reach full power by up to 7% whilst at the same time, improve overall efficiency by 7.1% during the engine speed transient.Copyright

A Numerical Study of the Flow Fields in a Highly Off-Design Variable Geometry Turbine

Conventionally, radial turbines have almost exclusively used radially fibred blades. While issues of mechanical integrity are paramount, there may be opportunities for improving turbine efficiency through a 3D blade design without exceeding mechanical limits. Off-design performance and understanding of the secondary flow structures now plays a vital role in the design decisions made for automotive turbocharger turbines. Of particular interest is extracting more energy at high pressure ratios and lower rotational speeds. Operating in this region means the rotor will experience high values of positive incidence at the inlet. A CFD analysis has been carried out on a scaled automotive turbine utilizing a swing vane stator system. To date no open literature exists on the flow structures present in a standard VGT system. Investigations were carried out on a 90 mm diameter rotor with the stator vane at the maximum, minimum and 25% mass flow rate positions. In addition stator vane endwall clearance existed at the hub side. From investigation of the internal flow fields of the baseline rotor, a number of areas that could be optimized in the future with three dimensional blading were identified. The blade loading and tip leakage flow near inlet play a significant role in the flow development further downstream at all stator vane positions. It was found that tip leakage flow and flow separation at off-design conditions could be reduced by employing back swept blading and redistributing the blade loading. This could potentially reduce the extent of the secondary flow structures found in the present study.Copyright

An Investigation Into Improving Off-Design Performance in a Turbocharger Turbine Utilizing Non-Radial Blading

Off-design performance now plays a vital role in the design decisions made for automotive turbocharger turbines. Of particular interest is extracting more energy at high pressure ratios and lower rotational speeds. In this region of operation the U/C value will be low and the rotor will experience high values of positive incidence at the inlet. The positive incidence causes flow to separate on the suction surface and produces high blade loading at inlet, which drives tip leakage. A CFD analysis has been carried out on a number of automotive turbines utilizing non-radial fibred blading. To help improve secondary flows yet meet stress requirements a number of designs have been investigated. The inlet blade angle has been modified in a number of ways. Firstly, the blading has been adjusted as to provide a constant back swept angle in the span wise direction. Using the results of the constant back swept blading studies, the back swept blade angle was then varied in the span wise direction. In addition to this, in an attempt to avoid an increase in stress, the effect of varying the leading edge profile of the blade was investigated. It has been seen that off-design performance is improved by implementing back swept blading at the inlet. Varying the inlet angle in the span wise direction provided more freedom for meeting stress requirements and reduces the negative impact on blade performance at the design point. The blade leading edge profile was seen to offer small improvements during off-design operation with minimal effects on stress within the rotor. However, due to the more pointed nature of the leading edge, the rotor was less tolerant to flow misalignment at the design point.Copyright

A Numerical and Experimental Performance Comparison of an 86 MM Radial and Back Swept Turbine

This report details the numerical and experimental investigation of the performance characteristics of a conventional radial turbine compared with a new back swept design for the same application. The blade geometry of an existing turbine from a turbocharger was used as a baseline. A new back swept blade was subsequently designed for the rotor, which departed from the conventional radial inlet blade angle to incorporate a 25° inlet blade angle. A comparative numerical analysis between the two geometries is presented. Results show that the 25° back swept blade offers significant increases in efficiency while operating at lower than optimum velocity ratios (U/C). Improvements in efficiency at off-design conditions could significantly improve turbocharger performance since the turbine typically experiences lower than optimum velocity ratios while accelerating during engine transients. A commercial CFD code was used to construct single passage steady state numerical models. The numerical predictions show off-design performance gains of 2% can be achieved, while maintaining design point efficiency. A finite element stress analysis was conducted to show that the nonradial inlet blade angle could be implemented without exceeding the acceptable stress levels for the rotor. A modal analysis was also carried out in order to identify the natural blade frequencies, showing that these were not significantly changed by the implementation of backswept blading. A prototype backswept rotor was produced and tested in a direct comparison with the baseline rotor geometry. Experimental performance results showed strong correlations with those obtained numerically, and verified the predicted performance gains at off-deign velocity ratios. This numerical and experimental study has shown that it is feasible from both an aerodynamic and structural point of view to improve the performance characteristic of a radial turbine at lower than optimum velocity ratios through the implementation of back swept blading.Copyright

Analysis of the Steady Flow Characteristics through a Poppet Valve

This paper describes the flow characteristics in the near throat region of a poppet valve under steady flow conditions. An experimental and theoretical procedure was undertaken to determine the total pressure at the assumed throat region of the valve, and also at a downstream location. Experiments of this type can be used to accurately determine the flow performance of a particular induction system. The static pressure recovery was calculated from the near throat region of the valve to the downstream location and was shown to be dependent on valve lift. Total pressure profiles suggest that for this particular induction system, the majority of pressure loss occurs downstream of the valve for lift/diameter ratios up to 0.1, and upstream of the valve for lift/diameter ratios greater than 0.1. Negligible pressure recovery was shown to exist from the cylindrical periphery of the valve head to the downstream location for all valve lifts, indicating that the flow had probably separated completely from the trailing edge of the valve seating face. The calculated discharge coefficients, based on the geometric throat static pressure measurements on the seating face, were in general less than those determined using the downstream static pressure, by as much as 12% in some instances towards the valves lower mass flow rate range.

The Evaluation of Discharge Coefficients in the Cylinders of High Performance Two-Stroke Engines

This paper presents a discussion of the difficulties in evaluating the discharge coefficients of ports in the cylinder wall of high performance two-stroke engines. Traditionally such evaluation requires the knowledge of the area of the port on a chord normal to the direction of flow through the port. However, due to the complex shape of ports in these engines, it is difficult to know the exact flow direction without some kind of flow analysis. Results of a study conducted on various methods of obtaining the port area either by assuming a flow direction or using geometrical information are presented. From the information presented it can be seen that the use of wall area is quite acceptable to determine discharge coefficients. This wall area requires no interpretation by the experimenter and therefore also permits a direct comparison with other ports. It is also required to know how these discharge coefficients are affected by both area ratio and pressure ratio in both flow directions for use in engine simulation. The paper reports on an investigation of a cylinder having 54 mm bore and 54.5 mm stroke. It has a basic port layout consisting of a bridged exhaust and five transfer ports (two side main, two side auxiliary and one central rear). The results are presented as 3D maps for every port within the cylinder. The influence of flow interaction between ports is also highlighted with results of the two adjacent side transfer ports measured together being presented.