Fakhri J. Hamady

Fabrication and Characterization of Micro-Orifices for Diesel Fuel Injectors

Stringent emission standards are driving the development of diesel-fuel injection concepts to mitigate in-cylinder formation of particulates. While research has demonstrated significant reduction in particulate formation using micro-orifice technology, implementation requires development of industrial processes to fabricate micro-orifices with diameters as low as 50 gmm and with large length-to-diameter ratios. This paper reviews the different processes being pursued to fabricate micro-orifices and the advanced techniques applied to characterize the performance of micro-orifices. The latter include the use of phase-contrast x-ray imaging of electroless nickel-plated, micro-orifices and laser imaging of fuel sprays at elevated pressures. The experimental results demonstrate an industrially viable process to create small uniform orifices that improve spray formation for fuel injection.

The Effect of Piston Bowl and Spray Configuration on Diesel Combustion and Emissions

A numerical and experimental study of the effect of piston bowl and spray configuration on diesel combustion and emissions has been conducted. The objective of this study is to gain better understanding of the effect of the piston bowl shape and fuel injector configuration on fuel-air mixing, combustion, and emissions in a diesel engine. Ideally, a uniform fuel-air mixture in the cylinder is desired to prevent the formation of regions containing a rich mixture, where soot is usually formed, and regions of lean mixtures, where nitrogen oxides are formed. Different piston bowl shapes and fuel injectors (number of nozzles, spray angle) have been considered and simulated using computational fluid dynamics and experiments. CFD calculations of fuel mass fraction, and measurements of cylinder pressure and emissions species are included. The results show that computer simulations coupled with experiments provide insight into the interactions between fluid flow, fuel-air mixing, combustion, and emissions.Copyright

Numerical Study to Achieve Stratified EGR in Engines

Exhaust Gas Re-circulation (EGR) has been used in intemal combustion engines to control automotive emissions. EGR is usually used to dilute the inlet charge, which consists of air, by redirecting part of the exhaust into the inlet manifold of the engine. This results in a reduction of the oxygen mass fraction in the inlet charge. However, dilution of the air-fuel mixture in an engine using stratified EGR could offer significant fuel economy saving comparable to lean burn or stratified charge direct-injection SI engines. The most critical challenge is to keep the EGR and air-fuel mixture separated, or to minimize the mixing between the two zones to an acceptable level for stable and complete combustion. Swirl-type stratified EGR and fuel-air flow structure is considered desirable for this purpose, because the circular shape of the cylinder tends to preserve the swirl motion. Moreover, the axial piston motion has minimal effect on the swirling motion of the fluid in the cylinder. In this study, we consider intake system design in order to generate a two-zone combustion system, where EGR is maintained in a layer on the periphery of the cylinder, and the fuel-air mixture is maintained in the center of the cylinder. KIVA-3V was used to perform numerical simulations on different EGR systems. The simulations were performed to determine if the two-zones can be generated in the cylinder, and to what extent mixing between the two zones occurs. For the engine geometries considered in this study, the results showed that it is possible to generate the two zones, but mixing is difficult to control.Copyright