Nicholas Mitroglou

Spray Characteristics of a Multi-hole Injector for Direct-Injection Gasoline Engines

Abstract The sprays from a high-pressure multi-hole nozzle injected into a constant-volume chamber have been visualized and quantified in terms of droplet velocity and diameter with a two-component phase Doppler anemometry (PDA) system at injection pressures up to 200 bar and chamber pressures varying from atmospheric to 12 bar. The flow characteristics within the injection system were quantified by means of a fuel injection equipment (FIE) one-dimensional model, providing the injection rate and the injection velocity in the presence of hole cavitation, by an in-house three-dimensional computational fluid dynamics (CFD) model providing the detailed flow distribution for various combinations of nozzle hole configurations, and by a fuel atomization model giving estimates of the droplet size very near to the nozzle exit. The overall spray angle relative to the axis of the injector was found to be almost independent of injection and chamber pressure, a significant advantage relative to swirl pressure atomizers. Temporal droplet velocities were found to increase sharply at the start of injection and then to remain unchanged during the main part of injection, before decreasing rapidly towards the end of injection. The spatial droplet velocity profiles were jet-like at all axial locations, with the local velocity maximum found at the centre of the jet. Within the measured range, the effect of injection pressure on droplet size was rather small while the increase in chamber pressure from atmospheric to 12 bar resulted in much smaller droplet velocities, by up to four-fold, and larger droplet sizes by up to 40 per cent.

Characterization of string cavitation in large-scale Diesel nozzles with tapered holes

The cavitation structures formed inside enlarged transparent replicas of tapered Diesel valve covered orifice nozzles have been characterized using high speed imaging visualization. Cavitation images obtained at fixed needle lift and flow rate conditions have revealed that although the conical shape of the converging tapered holes suppresses the formation of geometric cavitation, forming at the entry to the cylindrical injection hole, string cavitation has been found to prevail, particularly at low needle lifts. Computational fluid dynamics simulations have shown that cavitation strings appear in areas where large-scale vortices develop. The vortical structures are mainly formed upstream of the injection holes due to the nonuniform flow distribution and persist also inside them. Cavitation strings have been frequently observed to link adjacent holes while inspection of identical real-size injectors has revealed cavitation erosion sites in the area of string cavitation development. Image postprocessing has...

Internal flow and cavitation in a multi-hole injector for gasoline direct-injection engines

A transparent enlarged model of a six-hole injector used in the development of emerging gasoline direct-injection engines was manufactured with full optical access. The working fluid was water circulating through the injector nozzle under steady-state flow conditions at different flow rates, pressures and needle positions. Simultaneous matching of the Reynolds and cavitation numbers has allowed direct comparison between the cavitation regimes present in real-size and enlarged nozzles. The experimental results from the model injector, as part of a research programme into second-generation direct-injection spark-ignition engines, are presented and discussed. The main objective of this investigation was to characterise the cavitation process in the sac volume and nozzle holes under different operating conditions. This has been achieved by visualizing the nozzle cavitation structures in two planes simultaneously using two synchronised high-speed cameras. Imaging of the flow inside the injector nozzle identified the formation of three different types of cavitation as a function of the cavitation number, CN. The first is needle cavitation, formed randomly at low CN (0.5-0.7) in the vicinity of the needle, which penetrates into the opposite hole when it is fully developed. The second is the well known geometric cavitation originating at the entrance of the nozzle hole due to the local pressure drop induced by the nozzle inlet hole geometry with its onset at around CN=0.75. Finally, and at the same time as the onset of geometric cavitation, string type cavitation can be formed inside the nozzle sac and hole volume having a strong swirl component as a result of the large vortical flow structures present there; these become stronger with increasing CN. Its link with geometric cavitation creates a very complex two-phase flow structure in the nozzle holes which seems to be responsible for hole-to-hole and cycle-to-cycle spray variations.

Mixture distribution in a multi-valve twin-spark ignition engine equipped with high-pressure multi-hole injectors

Laser-induced fluorescence has been mainly used to characterise the two-dimensional fuel vapour concentration inside the cylinder of a multi-valve twin-spark ignition engine equipped with high-pressure multi-hole injectors. The effects of injection timing, in-cylinder charge motion and injector tip layout have been quantified. The flexibility in nozzle design of the multi-hole injectors has proven to be a powerful tool in terms of matching overall spray cone angle and number of holes to specific engine configurations. Injection timing was found to control spray impingement on the piston and cylinder wall, thus contributing to quick and efficient fuel evaporation. It was confirmed that in-cylinder charge motion plays a major role in engines stable operation by assisting in the transportation of the air-fuel mixture towards the ignition locations (i.e. spark-plugs) in the way of a uniformly distributed charge or by preserving stratification of the charge depending on operating mode of the engine.

Mapping of cavitating flow regimes in injectors for medium-/heavy-duty diesel engines

Reducing the sac volume size of medium-/heavy-duty diesel engine injector nozzles can minimise the fuel dripping into the combustion chamber at the end of injection events, which has been linked to reduced engine-out emissions. This study demonstrates the effect of reduction in the sac volume of diesel fuel injectors utilised in medium-/heavy-duty applications on the internal nozzle flow. This is realised by comparison of two heavy-duty diesel nozzles that feature a large difference in sac volume size of almost three times. For visualisation purposes, the nozzles have been enlarged by six times, and replicas were manufactured from a transparent material. High-speed digital imaging was used to capture the instantaneous spatial and temporal characteristics of geometric as well as dynamic vortex cavitation structures. The investigation was conducted in a steady-state flow test rig for three different needle valve lifts. For all tested conditions, the flow behaviour was analysed at three distinct areas of the nozzle, these being the needle seat, the sac volume and the injection hole. Interpretation of experimental observations was supported by parallel computational fluid dynamics simulations of the exact conditions measured during the experiments. Post-processing of the captured images has revealed the ensemble – average cavitation location, its standard deviation and the cavitation structures life – time inside the sac volume. Results showed a significant dependency of the internal nozzle flow on the sac volume size and identified clear differences in the structure of the cavitation pockets inside the sac volume under certain operating conditions.

Internal and near nozzle flow characteristics in an enlarged model of an outwards opening pintle-type gasoline injector

The internal nozzle and near the nozzle exit flows of an enlarged transparent model of an outwards opening injector were investigated for different flow rates and needle lifts under steady state flow conditions. A high resolution CCD camera, high speed video camera and an LDV system were employed to visualize the nozzle flow and quantify the tangential velocity characteristics. The images of the internal flow between the valve seat and the square cross-section end of the needle guide revealed the presence of four separated jet flows and four pairs of counter-rotating vortices with each pair bounded in-between two adjacent jets. The counter-rotating vortices are highly unstable with a circumferential oscillatory motion which was transmitted to the spray outside the nozzle with almost the same frequency. The dominant circumferential frequencies at the nozzle exit were identified by FFT analysis of the tangential velocities. A linear relationship exists between the dominant frequencies and the flow Reynolds number based on injection velocity and needle lift. Magnified images of the flow just outside the nozzle exit showed formation of interconnecting streamwise strings on the liquid film as soon as it emerges from the annular exit passage. The interspacing between the strings was found to be linearly related to injection velocity and almost independent of the needle lift.

Simulation of heating effects caused by extreme fuel pressurisation in cavitating flows through Diesel fuel injectors

Pressurization of Diesel fuel in modern common-rail injectors in excess of 2000bar can result to increased temperatures and significant variation of the fuel physical properties (density, viscosity, heat capacity and thermal conductivity) relative to those under atmospheric pressure and room temperature conditions while strong gradients are established due to the sharp de-pressurization of the fuel at the hole inlet. The subsequent acceleration at velocities reaching 700m/s is inducing wall friction and thus heating. Thus, the characteristics of cavitation taking place inside the injection holes are altered while the volumetric efficiency of the nozzle is significantly affected. The present study quantifies the role of these effects in mini sac-type Diesel injectors operating at pressures up to 2400bar through use of a RANS cavitation CFD model. The flow solver is accordingly modified to account for such effects. Two different injector designs have been considered: one with sharp-inlet cylindrical holes and one with tapered holes with inlet rounding. The results indicate significant changes in terms of the details of the flow development but also to bulk flow characteristics such as the volumetric efficiency of the injectors and the mean fuel injection temperature relative to the isothermal/constant properties case.

Derivation of flow related risk indices for stenosed left anterior descending coronary arteries with the use of computer simulations

The geometry of the coronary vessel network is believed to play a decisive role in the initiation, progression and outcome of coronary artery disease (CAD) and the occurrence of acute coronary syndromes (ACS). It also determines the flow field in the coronary artery which can be linked to CAD evolution. In this work geometric 3D models of left anterior descending (LAD) coronary arteries associated with either myocardial infarction (MI) or stable (STA) CAD were constructed. Transient numerical simulations of the flow for each model showed that specific flow patterns develop in different extent in the different groups examined. Recirculation zones, present distal the stenosis in all models, had larger extent and duration in MI cases. For mild stenosis (up to 50%) areas with low time averaged wall shear stress TAWSS (<0.15Pa) as well as areas with high TAWSS (>3Pa) appeared only in MI models; in moderate and severe stenosis (>50%) these areas were present in all models but were significantly larger for MI than STA models. These differentiations were expressed via numerical indices based on TAWSS, oscillating shear index (OSI) and relative residence time (RRT). Additionally we introduced the coagulation activation index (CAI), based on the threshold behaviour of coagulation initiation, which exceeded the suggested threshold only for MI models with intermediate stenosis (up to 50%). These results show that numerical simulations of flow can produce arithmetic indices linked with the risk of CAD complications.

Application of cone-beam micro-CT on high-speed Diesel flows and quantitative cavitation measurements

X-ray computed tomography (CT) is well-known and widely used in the medical sector for diagnosis of various illnesses. The technique is based on the absorption (i.e. attenuation) of the ionising electromagnetic radiation by the object. The amount of energy to be absorbed depends on the density and its thickness; the transmitted radiation through the object is then compared to the incident radiation that leads to a reconstruction of attenuation coefficients versus spatial position in the object. Thus, the resulting three-dimensional slices of the object are used (a) to identify internal geometric features of objects, and (b) to distinguish between media of different densities, i.e. liquid and air/vapour. In this study, the geometry extraction capability has been applied on time-averaged cavitation pocket shapes, as well as, the capability of density differentiation measurements on Diesel fuel flows. Results appear promising and pose a challenge in providing quantitative measurements of cavitation vapour fraction inside an injection hole.

Turbulence and Cavitation Suppression by Quaternary Ammonium Salt Additives

We identify the physical mechanism through which newly developed quaternary ammonium salt (QAS) deposit control additives (DCAs) affect the rheological properties of cavitating turbulent flows, resulting in an increase in the volumetric efficiency of clean injectors fuelled with diesel or biodiesel fuels. Quaternary ammonium surfactants with appropriate counterions can be very effective in reducing the turbulent drag in aqueous solutions, however, less is known about the effect of such surfactants in oil-based solvents or in cavitating flow conditions. Small-angle neutron scattering (SANS) investigations show that in traditional DCA fuel compositions only reverse spherical micelles form, whereas reverse cylindrical micelles are detected by blending the fuel with the QAS additive. Moreover, experiments utilising X-ray micro computed tomography (micro-CT) in nozzle replicas, quantify that in cavitation regions the liquid fraction is increased in the presence of the QAS additive. Furthermore, high-flux X-ray phase contrast imaging (XPCI) measurements identify a flow stabilization effect in the region of vortex cavitation by the QAS additive. The effect of the formation of cylindrical micelles is reproduced with computational fluid dynamics (CFD) simulations by including viscoelastic characteristics for the flow. It is demonstrated that viscoelasticity can reduce turbulence and suppress cavitation, and subsequently increase the injector’s volumetric efficiency.