AVL1

Edition 05/2012
Engine Simulation Environment (ESE) Tutorial
AVL FIRE
VERSION 2011.1
AVL List Gmbh 2009. All right reserved
ESE - Tutorial
FIRE v2011.1
AVL LIST GmbH

Hans-List-Platz 1, A-8020 Graz, Austria
http://www.avl.com
AST Local Support Contact: www.avl.com/ast-worldwide
Revision
Date
Description
Document No.
A
B
C
D
E
30-Jun-2008
15-Apr-2009
30-Nov-2010
14-Oct-2011
30-Apr-2012
FIRE v2008 ESE Tutorial

FIRE v2011.1 ESE Tutorial
08.0221.0860
08.0221.2009
08.0221.2010
08.0221.2011
08.0221.2011.1
Copyright 2012, AVL

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored
in a retrieval system or translated into any language or computer language, in any form or by any
means, electronic, mechanical, magnetic, optical, chemical, manual or otherwise, without prior
written consent of AVL.
This document describes how to run the FIRE software. It does not attempt to discuss all the
concepts of computational fluid dynamics required to obtain successful solutions. It is the users
responsibility to determine if he/she has sufficient knowledge and understanding of fluid dynamics
to apply this software appropriately.
This software and document are distributed solely on an "as is" basis. The entire risk as to their
quality and performance is with the user. Should either the software or this document prove
defective, the user assumes the entire cost of all necessary servicing, repair, or correction. AVL
and its distributors will not be liable for direct, indirect, incidental, or consequential damages
resulting from any defect in the software or this document, even if they have been advised of the
possibility of such damage.
FIRE is a registered trademark of AVL LIST. FIRE will be referred as FIRE in this manual.
All mentioned trademarks and registered trademarks are owned by the corresponding owners.
ESE - Tutorial
FIRE v2011.1
Table of Contents
1. Introduction _____________________________________________________1-1
1.1. Scope _______________________________________________________________________ 1-1
1.2. User Qualifications ___________________________________________________________ 1-1
1.3. Symbols _____________________________________________________________________ 1-1
1.4. Configurations _______________________________________________________________ 1-2
1.5. Documentation_______________________________________________________________ 1-2
2. ESE Diesel (922) _________________________________________________2-1

2.1. Overview ____________________________________________________________________ 2-1
2.2. Start ESE Session ____________________________________________________________ 2-3
2.2.1. Standalone Version for Linux ______________________________________________ 2-3
2.2.2. Standalone Version for Windows ___________________________________________ 2-3
2.3. Pre-processing _______________________________________________________________ 2-4
2.3.1. General Data _____________________________________________________________ 2-4
2.3.2. Sketcher _________________________________________________________________ 2-5
2.3.3. Mesher _________________________________________________________________ 2-10
2.3.4. Simulation Parameters ___________________________________________________ 2-12
2.3.5. Simulation ______________________________________________________________ 2-21
2.4. Post-Processing _____________________________________________________________ 2-23
2.4.1. Analyser ________________________________________________________________ 2-23
2.4.2. Report Generator ________________________________________________________ 2-27
3. ESE Diesel 02: ESE_D / BOOST coupling (927) ___________________3-1

3.1. Overview ____________________________________________________________________ 3-1
3.2. BOOST Model _______________________________________________________________ 3-2
3.3. Start ESE Diesel Session ______________________________________________________ 3-3
3.3.1. Standalone Version for Linux ______________________________________________ 3-4
3.3.2. Standalone Version for Windows ___________________________________________ 3-4
3.4. Pre-processing _______________________________________________________________ 3-4
3.4.1. General Data _____________________________________________________________ 3-5
3.4.2. Sketcher _________________________________________________________________ 3-5
3.4.3. Mesher __________________________________________________________________ 3-6
3.4.4. Simulation Parameters ____________________________________________________ 3-8
3.4.5. Simulation ______________________________________________________________ 3-11
3.5. Solver Run _________________________________________________________________ 3-14
3.6. Post-processing _____________________________________________________________ 3-14
3.6.1. Analyser (FIRE) _________________________________________________________ 3-14
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3.6.2. ROHR Treatment in BOOST______________________________________________ 3-18
4. ESE Aftertreatment (933) ________________________________________4-1

4.1. Overview ____________________________________________________________________ 4-1
4.2. DOC_DPF Example - Pre-processing ___________________________________________ 4-1
4.2.1. General System Data ______________________________________________________ 4-1
4.2.2. Assembler _______________________________________________________________ 4-2
4.2.3. Mesher __________________________________________________________________ 4-8
4.3. SCR Example Pre-processing _________________________________________________ 4-9
4.3.1. General System Data ______________________________________________________ 4-9
4.3.2. Assembler _______________________________________________________________ 4-9
4.3.3. Mesher _________________________________________________________________ 4-13
5. ESE Engine (961) ________________________________________________5-1

5.1. Simulation Domain - Overview_________________________________________________ 5-1
5.2. Meshing Strategy Overview __________________________________________________ 5-2
5.2.1. Grid generation concept ___________________________________________________ 5-2
5.2.2. Recommended File Structure on disk _______________________________________ 5-2
5.2.3. Workflow ________________________________________________________________ 5-3
5.3. Surface Preparation __________________________________________________________ 5-4
5.3.1. Selection Naming Conventions _____________________________________________ 5-7
5.4. Edge Preparation_____________________________________________________________ 5-7
5.5. Meshing Procedure ESE Engine Chamber Modeler ____________________________ 5-11
5.5.1. Overview _______________________________________________________________ 5-11
5.5.2. Create new project _______________________________________________________ 5-11
5.5.3. Edge Mesh ______________________________________________________________ 5-18
5.5.4. Movement ______________________________________________________________ 5-20
5.5.5. Port Connection _________________________________________________________ 5-24
5.5.6. Decoupled ports _________________________________________________________ 5-26
5.6. Meshing Procedure __________________________________________________________ 5-27
5.6.1. Create first dataset from 360 to 390 ______________________________________ 5-27
5.6.2. Create dataset from 550 to 582 ___________________________________________ 5-46
5.6.7. Create dataset from 60 to 144.2 __________________________________________ 5-70
5.6.9. Create dataset from 144.2 to 180 _________________________________________ 5-76
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5.6.10. Create dataset from 254 CA to 330 CA ___________________________________ 5-79

5.6.11. Create dataset from 180 to 254__________________________________________ 5-83
5.7. Ports _______________________________________________________________________ 5-89
5.7.1. Port Connection export ___________________________________________________ 5-89
5.7.2. Edge and Surface Preparation _____________________________________________ 5-90
5.7.1. Create mesh for intake and exhaust ports __________________________________ 5-92
5.7.1. Transfer intake and exhaust ports back ____________________________________ 5-94
5.8. Assembly ___________________________________________________________________ 5-96
5.8.1. Overview _______________________________________________________________ 5-96
5.8.2. Create new project _______________________________________________________ 5-96
5.8.3. Load Chamber Modeler project ____________________________________________ 5-96
5.8.4. Load Volume meshes _____________________________________________________ 5-97
5.8.5. Assemble and output _____________________________________________________ 5-99
5.9. Check list for grid generation ________________________________________________5-102
5.10. Mesh preparation for solver run ____________________________________________5-104
5.10.1. Change outlet boundary type during solver run ___________________________5-104
5.10.1. Exhaust valve opening _________________________________________________5-105
5.11. Solver GUI _______________________________________________________________5-107
5.11.1. Typical Boundary Conditions ___________________________________________5-107
5.11.2. Define Data for Calculation _____________________________________________5-107
5.11.3. Modules ______________________________________________________________5-118
5.11.4. Combustion ___________________________________________________________5-118
5.11.5. User defined parameters _______________________________________________5-119
5.11.6. Save Project___________________________________________________________5-119
5.12. Start Calculation __________________________________________________________5-119
5.12.1. Monitoring the Calculation _____________________________________________5-119
5.13. Post-processing ___________________________________________________________5-120
5.13.1. Load Results __________________________________________________________5-120
5.14. Geometry variation ________________________________________________________5-122
5.14.1. Intake port variation ___________________________________________________5-122
5.14.2. Piston bowl and squish design variation __________________________________5-125
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List of Figures
Figure 2-1: Diesel Cake - Overview ......................................................................................................................... 2-2
Figure 2-2: Diesel Cake Detail radius................................................................................................................... 2-2
Figure 2-3: General Mesh Properties ...................................................................................................................... 2-3
Figure 2-4: General Engine Parameters ................................................................................................................. 2-4
Figure 2-5: Piston Movement Specification............................................................................................................ 2-4
Figure 2-6: Piston Template Diesel Bowl 2 ......................................................................................................... 2-5
Figure 2-7: Piston Geometry Parameters ............................................................................................................... 2-6
Figure 2-8: Invariant Piston Parameters................................................................................................................ 2-6
Figure 2-9: Injector Geometry Parameters............................................................................................................. 2-7
Figure 2-10: Block Structure Parameters ............................................................................................................... 2-8
Figure 2-11: Piston Bowl - Final Shape .................................................................................................................. 2-8
Figure 2-12: Injector Location - Detail .................................................................................................................... 2-9
Figure 2-13: Sketcher Window - Selections Specification ..................................................................................... 2-9
Figure 2-14: Meshing Parameters ......................................................................................................................... 2-10
Figure 2-15: Moving Set Exemplary for range of 0 CA to 20 CA ..................................................................... 2-11
Figure 2-16: 3D Meshing Parameters ................................................................................................................... 2-12
Figure 2-17: Boundary Conditions Overview .................................................................................................... 2-12
Figure 2-18: Boundary Conditions Details ......................................................................................................... 2-13
Figure 2-19: Moving Wall Adiabatic Boundary Conditions.................................................................................. 2-13
Figure 2-20: Selections for Cyclic Boundary Conditions ..................................................................................... 2-13
Figure 2-21: Output Frequency Table Window.................................................................................................... 2-17
Figure 2-22: Nozzle - Diagrams - Injection Rate Table ....................................................................................... 2-21
Figure 2-23: Export Project.................................................................................................................................... 2-22
Figure 2-24: Job Setup Window ............................................................................................................................. 2-22
Figure 2-25: ESE Diesel Analyser Window........................................................................................................... 2-24
Figure 2-26: Mean Pressure Output ..................................................................................................................... 2-24
Figure 2-27: Mean Temperature Output .............................................................................................................. 2-25
Figure 2-28: Context Menu - Import Foreign Data ............................................................................................. 2-25
Figure 2-29: Comparison Simulation vs. Reference Data ................................................................................... 2-26
Figure 2-30: Quantity Plot Eq-T Mapping ........................................................................................................ 2-26
Figure 2-31: IMPRESS Chart Diagrams ............................................................................................................... 2-27
Figure 2-32: Header of ESE Diesel Report ........................................................................................................... 2-28
Figure 2-33: ESE Diesel Report Engine Specific Output ................................................................................. 2-28
Figure 2-34: ESE Diesel Report Exemplary Result at CA 718. 0 .................................................................... 2-29
Figure 3-1: Diesel Cake - Overview ......................................................................................................................... 3-2
Figure 3-2: BOOST Model tcimcc.bwf .................................................................................................................. 3-2
Figure 3-3: BOOST Combustion Model .................................................................................................................. 3-3
Figure 3-4: Simulation based on BOOST data ....................................................................................................... 3-4
Figure 3-5: BOOST Data Automatically Transferred to ESE Diesel ................................................................... 3-5
Figure 3-6: Sketcher - Bowl Specification ............................................................................................................... 3-5
Figure 3-7: Sketcher - Injector Specification .......................................................................................................... 3-6
Figure 3-8: Mesher - 2D and 3D Parameters.......................................................................................................... 3-7
Figure 3-9: ESE Diesel Delta Crank-Angle Table Modification ........................................................................... 3-8
Figure 3-10: Simulation Parameters before starting ESE Diesel - BOOST Coupling ....................................... 3-9
Figure 3-11: Simulation Parameters after Starting ESE Diesel - BOOST Coupling ....................................... 3-10
Figure 3-12: Data stored in cylinder_1_SHP.ssc file ........................................................................................... 3-11
Figure 3-13: Export Project.................................................................................................................................... 3-12
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Figure 3-14: Shell Output When Project is Saved ............................................................................................... 3-12

Figure 3-15: BOOST Simulation Control Firing Order Window .................................................................. 3-14
Figure 3-16: Cycle Simulation Output from BOOST........................................................................................... 3-14
Figure 3-17: ESE Diesel - Analyser Window ........................................................................................................ 3-15
Figure 3-18: Mean Pressure Output ..................................................................................................................... 3-16
Figure 3-19: Comparison between FIRE and BOOST post-cycle results in ESE Diesel Analyzer.................. 3-17
Figure 3-20: Comparison between FIRE and BOOST coupled results in IMPRESS Chart ............................ 3-18
Figure 4-1: ESE AT General System Data .......................................................................................................... 4-1
Figure 4-2: ESE AT StraightPipe: General Data ................................................................................................ 4-2
Figure 4-3: ESE AT StraightPipe: Inlet ............................................................................................................... 4-2
Figure 4-4: ESE AT StraightPipe: Outlet ............................................................................................................ 4-3
Figure 4-5: ESE AT StraightPipe_1: General Data ............................................................................................ 4-3
Figure 4-6: ESE AT StraightPipe_1: Outlet ........................................................................................................ 4-3
Figure 4-7: ESE AT CAT: General Data .............................................................................................................. 4-4
Figure 4-8: ESE AT StraightPipe_3: General Data ............................................................................................ 4-4
Figure 4-9: ESE AT StraightPipe_3: Outlet ........................................................................................................ 4-4
Figure 4-10: ESE AT BentPipe: General Data .................................................................................................... 4-4
Figure 4-11: ESE AT Viewer ................................................................................................................................. 4-5
Figure 4-12: ESE AT StraightPipe_4: General Data ........................................................................................... 4-5
Figure 4-13: ESE AT StraightPipe_4: Outlet ....................................................................................................... 4-5
Figure 4-14: ESE AT DPF: General ...................................................................................................................... 4-6
Figure 4-15: ESE AT DPF: Honeycomb Structure ............................................................................................. 4-6
Figure 4-16: ESE AT StraightPipe_6: General Data .......................................................................................... 4-6
Figure 4-17: ESE AT StraightPipe_6: Outlet ...................................................................................................... 4-6
Figure 4-18: ESE AT BentPipe_2: General Data ................................................................................................ 4-7
Figure 4-19: ESE AT StraightPipe_7: General Data .......................................................................................... 4-7
Figure 4-20: ESE AT Diesel Exhaust System: Surface....................................................................................... 4-7
Figure 4-21: ESE AT Diesel Exhaust System: Mesh .......................................................................................... 4-8
Figure 4-22: ESE AT Meshing Parameters: Resolution ..................................................................................... 4-8
Figure 4-23: ESE AT General System Data ........................................................................................................ 4-9
Figure 4-24: ESE AT Define File/Scaling........................................................................................................... 4-10
Figure 4-25: ESE AT Define Inlets/Outlets ....................................................................................................... 4-10
Figure 4-26: ESE AT Define Selections ............................................................................................................. 4-11
Figure 4-27: ESE AT Define Inlets/Outlets ....................................................................................................... 4-11
Figure 4-28: ESE AT Assembler Tree ................................................................................................................ 4-12
Figure 4-29: ESE AT StraightPipe - General Data ........................................................................................... 4-12
Figure 4-30: ESE AT StraightPipe_1: General Data ........................................................................................ 4-12
Figure 4-31: ESE AT StraightPipe_1: Outlet .................................................................................................... 4-12
Figure 4-32: ESE AT Assembler ......................................................................................................................... 4-13
Figure 4-33: ESE AT Mesher .............................................................................................................................. 4-13
Figure 4-34: ESE AT Selection Definition ......................................................................................................... 4-14
Figure 4-35: ESE AT Edit Surface Selections ................................................................................................... 4-14
Figure 4-36: ESE AT Meshing Parameters: Resolution ................................................................................... 4-15
Figure 5-1: Simulation Domain ................................................................................................................................ 5-1
Figure 5-2: Surface Mesh.......................................................................................................................................... 5-3
Figure 5-3: Surface check (invalid surface versus correct surface input) ............................................................ 5-4
Figure 5-4: Surface does not fulfill check criteria .................................................................................................. 5-5
Figure 5-5: Required selections on the input surface ............................................................................................ 5-6
Figure 5-6: Edges input for ESE Engine Chamber Modeler ................................................................................. 5-8
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Figure 5-7: Selections on the input edges ............................................................................................................... 5-8

Figure 5-8: Example 1 for edge definition on chamber for gasoline engine ........................................................ 5-8
Figure 5-9: Example 2 for edge definition on piston for gasoline engine ............................................................ 5-9
Figure 5-10: Example 3 for edge definition on piston for diesel engine............................................................... 5-9
Figure 5-11: Example 4 for edge definition on chamber for diesel engine .......................................................... 5-9
Figure 5-12: Example 5 for edge definition on chamber for gasoline engine .................................................... 5-10
Figure 5-13: Example for edge model as it must not be defined......................................................................... 5-10
Figure 5-14: Start ESE Engine Chamber Modeler .............................................................................................. 5-11
Figure 5-15: Create new ESE Engine project ....................................................................................................... 5-11
Figure 5-16: Create new ESE Engine project ....................................................................................................... 5-12
Figure 5-17: Save new ESE Engine project to sub-folder ................................................................................... 5-12
Figure 5-18: Surface Mesh loaded in ESE Engine GUI ....................................................................................... 5-13
Figure 5-19: Engine component Auto-assignment............................................................................................... 5-14
Figure 5-20: Engine component assignment manually ....................................................................................... 5-15
Figure 5-21: Incorrect assignment of selection to engine components .............................................................. 5-15
Figure 5-22: Correct assignment of selection to engine components ................................................................. 5-16
Figure 5-23: Edge mesh input section in menu bar ............................................................................................. 5-18
Figure 5-24: Load edge mesh ................................................................................................................................. 5-19
Figure 5-25: Characteristic edges .......................................................................................................................... 5-20
Figure 5-26: Virtual surface position option......................................................................................................... 5-20
Figure 5-27: Movement definition for the piston ................................................................................................. 5-21
Figure 5-28: Intake valve lift curve at valve open................................................................................................ 5-22
Figure 5-29: Supported and not supported valve lift shape ................................................................................ 5-22
Figure 5-30: Setup Intake valve movement .......................................................................................................... 5-23
Figure 5-31: Setup Exhaust valve movement....................................................................................................... 5-23
Figure 5-32: Valve opening visualized in Time Line ........................................................................................... 5-24
Figure 5-33: Port connection setup for intake valve 1 ........................................................................................ 5-24
Figure 5-34: Port connection setup for intake valve 1 (detailed view) .............................................................. 5-25
Figure 5-35: Port connection setup as it should not be defined ......................................................................... 5-25
Figure 5-36: Port connection setup for exhaust valves ....................................................................................... 5-25
Figure 5-37: Adaption of topology for intake valve 1........................................................................................... 5-26
Figure 5-38: Decoupled ports - exhaust seat topology ......................................................................................... 5-27
Figure 5-39: Empty Time Line............................................................................................................................... 5-27
Figure 5-40: Valve opening visualized in Time Line ........................................................................................... 5-28
Figure 5-41: Create dataset from 360CA to 390 CA .......................................................................................... 5-28
Figure 5-42: New dataset from 360CA to 390 CA.............................................................................................. 5-28
Figure 5-43: 2D valve seat mesh at 370 CA ......................................................................................................... 5-30
Figure 5-44: Adaption of topology @ 360 CA ...................................................................................................... 5-30
Figure 5-45: Insert a new marker at the valve corner ......................................................................................... 5-31
Figure 5-46: Copy settings from intake valve 1.................................................................................................... 5-31
Figure 5-47: 2D exhaust valve seat mesh at 370 CA .......................................................................................... 5-32
Figure 5-48: 2D intake valve seat mesh at 370 CA ............................................................................................. 5-32
Figure 5-49: Incorrect setup of 2D valve topology ............................................................................................... 5-33
Figure 5-50: Choose 2D template section either in Time line or via menu bar ................................................ 5-33
Figure 5-51: 2D template ........................................................................................................................................ 5-34
Figure 5-52: Error message if input is missing .................................................................................................... 5-34
Figure 5-53: Circular edge definition missing ...................................................................................................... 5-35
Figure 5-54: Correct setup of circular edge definition ......................................................................................... 5-35
Figure 5-55: Break lock option on right mouse button ....................................................................................... 5-35
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Figure 5-56: 2D template w/o (left side) and with (right side) squish edge ....................................................... 5-36
Figure 5-57: 3D template structure (schematic description) .............................................................................. 5-36
Figure 5-58: 3D template after setting subdivisions for AB, BC and CD .......................................................... 5-37
Figure 5-59: Unfavorable 3D template configuration ......................................................................................... 5-38
Figure 5-60: Adjustment of point B ....................................................................................................................... 5-38
Figure 5-61: Layer alignment after moving point B upwards ............................................................................ 5-39
Figure 5-62: Recommended 3D template configuration ...................................................................................... 5-39
Figure 5-63: Selected layer is highlighted ............................................................................................................. 5-40
Figure 5-64: Click to assign layer to circular edge ............................................................................................... 5-40
Figure 5-65: Layer successfully assigned to characteristic edges ....................................................................... 5-40
Figure 5-66: Edge Constraints table ..................................................................................................................... 5-41
Figure 5-67: Not favorable setup of edge constraints .......................................................................................... 5-41
Figure 5-68: Recommended setup of edge constraints ........................................................................................ 5-41
Figure 5-69: Start 3D template generation .......................................................................................................... 5-42
Figure 5-70: 3D start topology ............................................................................................................................... 5-43
Figure 5-71: 3D mesh generation finished............................................................................................................ 5-43
Figure 5-72: Mesh movement setup ...................................................................................................................... 5-44
Figure 5-73: Mesh movement progress window ................................................................................................... 5-45
Figure 5-74: Mesh movement message/logging area ........................................................................................... 5-45
Figure 5-75: Dataset completed ............................................................................................................................. 5-46
Figure 5-76: Detailed summary information for each mesh position ................................................................ 5-46
Figure 5-77: Mirror dataset about intake valve 1 ................................................................................................ 5-47
Figure 5-78: Dataset range at intake valve closing ............................................................................................... 5-47
Figure 5-80: Warning message............................................................................................................................... 5-48
Figure 5-81: Correct block corners in 2D valve mesh .......................................................................................... 5-48
Figure 5-82: Dataset 550 CA to 582 CA .............................................................................................................. 5-50
Figure 5-84: Insert a new marker at the valve corner ......................................................................................... 5-51
Figure 5-85: 2D valve seat mesh at 390 CA, 420 CA and 470 CA ................................................................... 5-52
Figure 5-87: Selected layer is highlighted ............................................................................................................. 5-54
Figure 5-88: 3D start topology configuration ....................................................................................................... 5-55
Figure 5-89: Mesh movement - Advanced options ............................................................................................... 5-56
Figure 5-90: Simplified description of the interpolation layers in the cylinder without overlapping layers . 5-57
Figure 5-91: Simplified description of the interpolation layers in the cylinder with overlapping layers ....... 5-57
Figure 5-92: Mesh interpolation information ....................................................................................................... 5-58
Figure 5-93: ............................................................................................................................................................... 5-59
Figure 5-94: Dataset from compression stroke mirrored to expansion stroke................................................... 5-62
Figure 5-95: 2D valve seat topology for closed valves ........................................................................................... 5-62
Figure 5-97: 2D valve seat topology for closed valves ........................................................................................... 5-66
Figure 5-98: Activate local refinement in 2D template ........................................................................................ 5-67
Figure 5-99: Define local refinement in 2D template ........................................................................................... 5-67
Figure 5-100: Options for local refinement in 2D template after first refinement is defined .......................... 5-68
Figure 5-101: Adjustment of point B ..................................................................................................................... 5-68
Figure 5-102: 3D start topology with local refinement around spark location ................................................. 5-69
Figure 5-103: Detach dataset ................................................................................................................................. 5-70
Figure 5-104: Modify dataset upper value ............................................................................................................ 5-71
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Figure 5-105: Dataset range at exhaust valve closing .......................................................................................... 5-72

Figure 5-106: Adjustment of block corners for exhaust valve closing................................................................ 5-73
Figure 5-108: Project status after movement of dataset 330 CA 360 CA ..................................................... 5-76
Figure 5-110: 3D template layout for dataset 144.2 CA to 180 CA .................................................................. 5-78
Figure 5-111: Create dataset from 254CA to 330 CA ........................................................................................ 5-79
Figure 5-112: Adjustment of block corners for exhaust valve ............................................................................ 5-80
Figure 5-114: 3D template for dataset 254 CA - 330 CA ................................................................................... 5-82
Figure 5-115: Moved dataset 254 CA to 330 CA ................................................................................................ 5-83
Figure 5-116: Warning message that dataset will be cropped ............................................................................. 5-84
Figure 5-118: 3D template layout for dataset 180 CA to 254 CA ..................................................................... 5-86
Figure 5-119: Moved dataset 180 CA to 254 CA ................................................................................................ 5-87
Figure 5-120: According to status mesh movement needs to be checked .......................................................... 5-88
Figure 5-121: Port connection export ................................................................................................................... 5-89
Figure 5-122: Close ESE Engine Chamber Modeler ............................................................................................ 5-90
Figure 5-123: Rotate intake port surface and edge model .................................................................................. 5-90
Figure 5-124: Edge and surface model for intake port ........................................................................................ 5-91
Figure 5-125: Selections on the intake port surface ............................................................................................ 5-91
Figure 5-126: Edge and surface model for intake port ........................................................................................ 5-92
Figure 5-127: Start ESE Engine Chamber Modeler ............................................................................................ 5-92
Figure 5-128: Load FAME Hexa settings for the intake ports ........................................................................... 5-93
Figure 5-129: Start FAME Hexa grid generations ............................................................................................... 5-93
Figure 5-130: Load FAME Hexa settings for the exhaust ports ......................................................................... 5-94
Figure 5-131: Rotate ports back to original position ........................................................................................... 5-94
Figure 5-132: Static intake and exhaust ports generated with FAME Hexa .................................................... 5-95
Figure 5-133: Start ESE Engine Model Assembler.............................................................................................. 5-96
Figure 5-134: Open ESE Engine Chamber Modeler project ............................................................................... 5-97
Figure 5-135: Open ESE Engine Chamber Modeler project ............................................................................... 5-97
Figure 5-136: Load intake port mesh .................................................................................................................... 5-98
Figure 5-137: Correctly loaded volume meshes.................................................................................................... 5-98
Figure 5-138: Wrong placed volume meshes ........................................................................................................ 5-99
Figure 5-139: Activate decoupled ports ................................................................................................................. 5-99
Figure 5-140: Create new ESE Engine Model Assembler folder ........................................................................ 5-99
Figure 5-141: Create new ESE Engine project ................................................................................................... 5-100
Figure 5-142: Model assembling process status information ............................................................................ 5-100
Figure 5-143: Check information written to <filename>_results.txt file ....................................................... 5-101
Figure 5-144: Moving mesh loaded in FMO Editor ........................................................................................... 5-104
Figure 5-145: Clear selection BND_Outlet ......................................................................................................... 5-105
Figure 5-146: Exhaust valve seat before (left) and at valve opening (right) @ 144.2CA .............................. 5-105
Figure 5-147: Add cell selection at exhaust valve seats ..................................................................................... 5-106
Figure 5-148: Valve gap region without (left) and with (right) smoothing @EVO ........................................ 5-106
Figure 5-149: Smoothing exhaust valve seat area @864.4CA ......................................................................... 5-114
Figure 5-150: Log Monitoring Window ............................................................................................................... 5-119
Figure 5-151: Plane cut Velocity at 470 CA.................................................................................................... 5-121
Figure 5-152: Intake port (injector) design variation ........................................................................................ 5-122
Figure 5-153: Start ESE Engine Component Modeler ...................................................................................... 5-122
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Figure 5-154: ESE Engine Component Modeler, port cutter ........................................................................... 5-124
Figure 5-155: Piston bowl and squish area modification .................................................................................. 5-125
Figure 5-156: ESE Engine Component Modeler, surface exchange ................................................................. 5-127
Figure 5-157: 2D template for baseline and modified chamber design ............................................................ 5-127
Figure 5-158: Data transfer and initial valve mesh finished ............................................................................ 5-128
Figure 5-159: Intake valve mesh on new surface ............................................................................................... 5-128
Figure 5-160: Execute all ...................................................................................................................................... 5-129
Figure 5-161: Chamber Modeler project done for surface variant .................................................................... 5-129
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1. INTRODUCTION
This manual describes the ESE (Engine Simulation Environment) tutorial examples.
1.1. Scope
This manual describes examples using FIRE Workflow Manager to create meshes and
simulate fluid systems. It does not attempt to discuss all the concepts of computational
fluid dynamics required to obtain successful solutions. It is the users responsibility to
determine if he/she has sufficient knowledge and understanding of fluid dynamics to apply
this software appropriately.
1.2. User Qualifications

Users of this manual:
Must be qualified in basic Linux and/or Windows.
Must be qualified in basic CFD (Computational Fluid Dynamics).
This document is a basic qualification for operating the FIRE Workflow

Manager and users are recommended to continue with basic and advanced
training courses.
1.3. Symbols
The following symbols are used throughout this manual. Safety warnings must be strictly
observed during operation and service of the system or its components.
Caution: Cautions describe conditions, practices or procedures which

could result in damage to, or destruction of data if not strictly observed or
remedied.
Note: Notes provide important supplementary information.
Convention
Meaning
Italics
For emphasis, to introduce a new term or for manual

titles.
monospace
To indicate a command, a program or a file name,

messages, input / output on a screen, file contents or
object names.
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A MenuOpt font is used for the names of menu options,

submenus and screen buttons.
1.4. Configurations
Software configurations described in this manual were in effect on the publication date.
It is the users responsibility to verify the configuration of the equipment before applying
procedures.
1.5. Documentation
FIRE documentation is available in PDF format and consists of the following:
Primary Information
Release Notes
Validation Report
Installation Guide
Licensing Users Guide
System Requirements and Supported Platforms
Getting Started
Primer
Modules
ESE Tutorials
Macro Tutorial
Application Examples
GUI Pre/Post-processing
FIRE Workflow Manager Users Guide

CFD Tools Users Guide:
2D Sketcher
CAD Data Manager
Engine Simulation Environment (ESE) Tools:
ESE Aftertreatment
ESE Diesel
ESE Engine
FAME Grid Generation:
FAME Hexa
FAME Topo
FAME Tetra
FAME Wrapper
Computational Aero Acoustics (CAA)
DoE and Optimization
CFD Solver
Combustion / Emission Module

Coupling Module CAE:
1D/3D Coupling
AVL Code Coupling (ACCI)
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CFD/FEA Coupling
De-icing / De-fogging Module
Electrification & Hybridization:
Battery Module
PEM Fuel Cells Module
Electromagnetic Module
Eulerian Multiphase Module
Exhaust Gas Aftertreatment Module
Lagrangian Multiphase Module:
Spray
Wallfilm
Main Program:
CFD Solver
General Gas Phase Reactions
Porosity
Heat Exchanger
Radiation
Single Phase Boiling
Species Transport
Thin Walls
User-Functions
Known Issues are available on the AST Service World Knowledge Base:
Link to FIRE Known Issues
Release Notes will only be available for Service Packs and all manuals will be updated for
the following release version.
We Want to Hear from You

Your comments and suggestions help us to improve the quality and practical
relevance of our documentation.
If you have any suggestions for improvement, please send them to:
ast_doc@avl.com
We look forward to hearing from you.
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2. ESE DIESEL (922)

This chapter describes the systematic workflow of a FIRE diesel combustion simulation
using the Engine Simulation Environment Diesel ESE Diesel. The required input data,
special topology of the calculation mesh and settings for some simulation models are
discussed.
It is recommended that the user has a basic understanding of the FIRE Workflow Manager
Users Guide and has completed the Primer examples before beginning this example.
When using simulation tools for diesel combustion it is always necessary to perform an
adjustment of the input data for the calculation models to fit the computed results to
measurements or visualization data. This is an interactive and engine specific process,
which makes it very difficult to develop a standardized adjustment strategy.
ESE Diesel is the first CFD simulation tool, which allows beginners, intermediate users
and experts to set up, perform and analyze the injection and combustion process in diesel
engines reliably and accurately with minimum effort.
Although extremely simple to handle, online help is offered to assist the users of our
software in any situation, giving general information about the product and explaining
details useful to know for making use of all the capabilities of the tool.
2.1. Overview
For diesel combustion simulation the calculation of the intake stroke is usually not
performed in order to reduce calculation time. This means that the calculation starts at
inlet valve closure (IVC).
A simplified geometry is used to reduce the effort for mesh generation. Details like intake
ports and valves (valve reliefs) are not considered (refer to Figure 2-1).
For a centric and rotational symmetric combustion chamber and if the fuel mass flow is
the same for all holes of the injector, only a segment of the geometry for one injected spray
can be used. The angle of the segment is given by the number of holes in the injection
nozzle (angle = 360/number of nozzle holes).
The mesh density in the region of the spray should have approximately ten times the
diameter of the nozzle hole. If a segment with an angle of 45 [deg.] is used a subdivision of
about 17 cell layers in polar direction is a good recommendation because an uneven
number of subdivisions allows to inject within a cell layer and not along cell faces.
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Figure 2-1: Diesel Cake - Overview

When modeling the mesh near the cylinder axis as polar mesh instead of a cake topology a
small radius of about 0.3 [mm] at the cylinder axis avoids the cells of zero cell faces near
the cylinder axis (refer to Figure 2-2). The effect of numerical diffusion, which is seen
when the spray does not pass the cell faces perpendicular (worst case 45 [deg.]), can be
avoided.
Figure 2-2: Diesel Cake Detail radius

Penetration length and breakup behavior show a more realistic view if they are compared
with measurements and visualization data.
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The ground of the bowl should be meshed with at least one continuous layer for a proper
calculation of the heat transfer through the piston wall.
To get the correct compression ratio in the model without changing the characteristics of
the flow field in the bowl (squish flow), a compensation volume is added at the outer part
of the geometry. This volume accounts for geometrical details, which cannot be considered
in this segment approach. This compensation part should have at least three cell layers in
radial direction.
Figure 2-3: General Mesh Properties
2.2. Start ESE Session

2.2.1. Standalone Version for Linux
1.
Open a new shell window.
2.
Type the following command to start ESE Diesel standalone version:

fire_ese_diesel
2.2.2. Standalone Version for Windows

To start ESE Diesel double click on the AVL-AST icon on the desktop to open the AST
Launcher. Move the mouse over the FIRE icon to pop-up the list of program parts and then
select ESE Diesel.
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2.3. Pre-processing
To start a new session, please select radio buttons for Engine segment simulation and
Standard engine segment simulation.
During the pre-processing the user is guided through the following sections:
General data
Sketcher
Mesher
Simulation parameter
The relevant window can be changed by selecting Next Page on the lower right position of
the window.
2.3.1. General Data

The General data allows the user to specify General parameters of the engine simulated
in the present project, i.e., data which is characteristic for this engine and therefore helps
to identify it among a number of previously performed or ongoing investigations.
Parameters are separated into two tabs:
General engine parameters tab contains input fields for engine name, number of
cylinders, bore, and compression ratio.
Piston movement specification contains input fields for crank radius, connecting rod
length, piston pin offset, etc.
Please enter the relevant input data as shown in Figure 2-4 and Figure 2-5, then select
Next Page.
Figure 2-4: General Engine Parameters
2-4
Figure 2-5: Piston Movement Specification
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2.3.2. Sketcher
The Sketcher enables the user to perform five tasks:
Define the piston bowl shape (Piston)
Define the injector shape (Injector)
Modify the block-structure of a template (Block structure)
Define details related to selections (Selections)
Fix the compression ratio for eventual contour changes (e.g. adjustment of actual
compression ratio will not be done trough adjustment of compensation volume but
trough changes of relevant (user defined) contour parameters) (Const CR)
Please perform the following steps to create the geometry:

1.
Select Create piston from template to list all available piston bowl templates with
sketches.
2.
The shape of Diesel Bowl 2 fits well to the geometry, which is investigated within this
example.
After selecting a template the parameterized curve describing the piston bowl shape is
shown in the Drawing area. In the Input area all parameters belonging to the selected
template (white input fields) and additional measures (gray fields) are listed. In the
lower part of the Input area a sketch of the template containing all parameter names
(black font) and measures (green font) is shown.
Figure 2-6: Piston Template Diesel Bowl 2

3. Enter the values shown in the following figure:
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Figure 2-7: Piston Geometry Parameters

4. Note that parameters, which appear in the lower part of the list (gray boxes), cannot be
modified. The values depend on other parameters and are only for information. For
these parameters, please refer to Figure 2-8.
Figure 2-8: Invariant Piston Parameters

The shape of an injector can be included into the description of the engine shape.
Injector models are available as template only. Each injector template is a
parameterized model consisting of a curve describing the shape of the injector.
2-6
5.
Select the Injector tab and select Create injector from template to list all available
injector templates with sketches.
6.
Select Injector 3 and specify all parameters for injector as shown in the following
figure:
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Figure 2-9: Injector Geometry Parameters

The Block structure tab enables the user to check and to influence the structure and
the quality of the computational grid, which will be created in the next step.
7.
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Select Under spray block and Under injector block and enter the parameters shown
in the following figures:
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Figure 2-10: Block Structure Parameters
8.
Note: If the default parameters do not give the right shape of the Piston
Bowl, activate Display / edit characteristic points and set them manually.
Activate toggle switch for Display characteristic points and check the final result
referring to Figure 2-11 and for detailed information of spray injector location refer to
Figure 2-12.
Spray axis
Figure 2-11: Piston Bowl - Final Shape

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Nozzle position
Figure 2-12: Injector Location - Detail

The Selections tab enables the user to create a predefined set of selections.
9.
Select Standard selections and Oil wetted liner selection and enter values as shown
in the following figure (default value distance from cylinder top to the first
compression ring is the distance where liner oil can not be displaced).
Figure 2-13: Sketcher Window - Selections Specification

10. Select Next Page to go to the Mesher window.
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2.3.3. Mesher
Based on the geometry description made above, a set of computational meshes covering
360oCA is created. The mesh generation process is divided into the creation of a 2D and a
3D mesh.
1. Under 2D parameters specify meshing parameters as shown in Figure 2-14. The
dependent averaged cell size has to be specified in a table (smaller avg. cell size is
defined for the mesh from 0 to 20deg CA, than a rezone is defined; meshes after
37.5deg CA (this is automatically rezone, where template 0 is changed to template 1)
are symmetrical compressed towards stroke center with a factor of 2).
Figure 2-14: Meshing Parameters

2.
2-10
Select Generate 2D meshes to create a set of 2D computational meshes covering the

compression and expansion stroke of a 4-stroke engine. The result of the mesh
generation process is displayed in the Drawing area.
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Each pair of 2D meshes belonging to the complete set of computational meshes can be
selected and displayed. Figure 2-15 shows exemplary the range for 0 deg CA to 20 deg
CA.
Note: Mesh sets cover the crank angle range from 0 to 360 deg CA. This
range is sufficient to cover the piston movement of the high pressure cycle
(from IVC to EVO). Program will automatically realize which mesh will be
the first to start the simulation with.
Figure 2-15: Moving Set Exemplary for range of 0 CA to 20 CA

4. Under 3D parameters define parameters like indicated on Fig 2-16a number of
subdivisions in angular direction has to be odd number to ensure more efficient 3D
post-processing in segment center line. Distribution in angular direction should be
light compressed (1.1) toward segment center by considering finer layer close to
periodic boundary face (2 deg size). Bowl center and injector shift are not considered
for this case (in this case a whole asymmetric bowl would be generated).
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Figure 2-16: 3D Meshing Parameters

5. Select Next Page to specify the simulation parameters.
2.3.4. Simulation Parameters

This is used for setting various simulation parameters. This window is the same as in the
FIRE Workflow Manager, refer to the FIRE Workflow Manager Users Guide for
information regarding simulation parameters.
Note: ESE Diesel uses default Case.ssf file for all new projects. The file can be found in
[ESE_INSTALLATION_DIR]/files/ESE/project_templates/DieselBowl/Calculation/Case
directory.
2.3.4.1. Overview of Typical Boundary Conditions

The wall (surface) temperatures (cylinder liner, cylinder head, piston) are based on
experimental experiences and depend on the operating point (load and speed). The
boundary conditions of the cylinder head are specified as fixed wall, the boundary
conditions of the piston bowl as moving wall.
Fixed wall
Cyclic
boundary
conditions
Moving wall
Fixed
adiabatic wall
Figure 2-17: Boundary Conditions Overview
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Symmetry boundary conditions are applied to the radius surface along the center axis of
the segment mesh. This symmetry boundary condition might cause problems with
calculation results regarding temperature. In this case adiabatic fixed wall boundary
conditions can be specified.
Fixed wall
Cyclic
boundary
conditions
Symmetry
boundary
conditions
Figure 2-18: Boundary Conditions Details

The boundary conditions concerning the additional compensation volume should be
applied in this way. Faces at the outer, inner and lower side of the volume have to be
specified as moving wall adiabatic (heat flux =0).
Cyclic
boundary
conditions
Fixed wall
Fixed wall
adiabatic
Moving wall
Moving wall
adiabatic
Figure 2-19: Moving Wall Adiabatic Boundary Conditions

The faces in polar direction are specified as cyclic boundary conditions.
Fixed wall
Cyclic
boundary
conditions
Fixed wall
adiabatic
Figure 2-20: Selections for Cyclic Boundary Conditions
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2.3.4.2. Define Data for Calculation

Enter the following input values for this example (values not specified are default):
2.3.4.2.1. Run Mode

Select Run mode in the parameter tree and then select Crank-Angle from the pull-down
menu.
Delta-alpha
Table
upto
Crank-Angle
upto
upto
upto
upto
upto
upto
upto
560
570
710
715
750
800
850
DeltaAlpha
0.5
1
1
0.5
0.25
0.5
1
Start angle
560
deg
End angle
850
deg
Speed
1800
1/min
2.3.4.2.2. Module Activation

Select Species transport, Combustion, Emissions and Spray.
2.3.4.2.3. Boundary Conditions

Specify values for Boundary Conditions as follows:
BND_Piston
BND_Liner
BND_Axis
2-14
Sel. for BC
BND_Piston
Name of BC
BND_Piston
Type of BC
Wall
Movement
Mesh Movement
Thermal
Temperature
Sel. for BC
BND_Liner
Name of BC
BND_Liner
Type of BC
Wall
Thermal
Temperature
Sel. for BC
BND_Axis
Name of BC
BND_Axis
Type of BC
Symmetry
570.15
470.15
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BND_Segment
_1
BND_Comp_
Vol
BND_Head
FIRE v2011.1
Sel. for BC
BND_Segment_1
Name of BC
BND_Segment_1
Type of BC
Inlet/Outlet
Inlet/Outlet
Periodic
Arbitrary
interface
Select Boundary_connection1 from the

pull-down menu and BND_Segment_2
appears in Sel. for shadow boundary.
Sel. for shadow

boundary
BND_Segment_2
Sel. for BC
BND_Comp_Vol
Name of BC
BND_Comp_Vol
Type of BC
Wall
Movement
Mesh Movement
Thermal
Heat Flux
Sel. for BC
BND_Head
Name of BC
BND_Head
Type of BC
Wall
Movement
Velocity
Thermal
Temperature
570.15
W/m
2.3.4.2.4. Fluid Properties (Air)

In the Fluid properties folder in the parameter tree, select FP[1]: NoName to access the
Fluid properties of input field. The Fluid properties of Air are selected automatically.
2.3.4.2.5. Initial Conditions

Select Initial conditions in the parameter tree to access the following input fields:
Pressure
256000
Velocity u
m/s
Density
kg/m
Velocity v
m/s
Temperature
386
Velocity w
m/s
Turb. kin. energy
10
m2/s2
Scalar
Turb. length scale
0.0045
Initialization mode
Swirl/Tumble
Swirl/Tumble
2880
Direction of rotation axes
X=0
Pa
3
1/min
Y=0
Z=-1
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1-Equation-turbulence
model
Deactivate
Reinitialization
Deactivate
Smoothing
Deactivated
Type of hydrocarbon fuel
DIESEL
EGR mass fraction
0.049
EGR composition
0.65
Equivalence ratio
Activate
Equivalence ratio
2.3.4.2.6. Solver Control

In the Solver control folder in the parameter tree, select the following in the parameter
tree to access the relevant input fields:
Discretisation
Equation control
Activate
equations
Underrelaxation
factors
Convergence
criteria
2-16
Simple/PISO
activated
Turbulence
k-zeta-f
Energy
Yes
Two stage pressure

correction
No
Momentum
0.6
Pressure
0.5
Turb. kin. energy
0.4
Turb. diss. rate
0.4
Energy
0.95
Mass source
Viscosity
Scalar
0.95
Species transport
equ.
0.95
Max. number of
iteration
100
Min. number of
iteration
10
Reduction of
residuals
Activated
Pressure (activate
toggle switch)
1e-002
Momentum
1e-002
Turb. kin. energy
Deactivate
Turb. diss. rate
Deactivate
Energy
Deactivate
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Continuity
Linear Solver
Scalar
Deactivate
AMG
Select
2.3.4.2.7. Output Control

For this example keep default settings for output to 2D result file.
Write 3D result file
.
Enter the values shown for Output frequency in a Table
Figure 2-21: Output Frequency Table Window

Select the following parameters:
Density
Yes
Mach number
No
Passive scalar
No
Pressure
Yes
Temperature
Yes
TKE and dissip. rate
Yes
Velocity
Yes
Viscosity
Yes
Vorticity
No
Wall heat transfer (greyed out)
Yes
Momentum error
Yes
Write restart file

Select Write restart file
Output frequency
10
Write backup file

Select Write backup file
Output frequency
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2.3.4.2.8. Modules
Refer to the relevant module manual for further information.
Module
Parameter
Tree
GUI Options
Action
Species
Transport
2D Results
Sum of mass fractions
Activate
Mean specific heat
Activate
Mean gas constant
Activate
Control
Extended output
On
Combustion
models
Coherent Flame Model
Activate/ECFM-3Z
Mixing model par.

Ignition Model
Auto Ign. param.
Chemical reac. time
Extinction temp.
0.8
NO models
Extended Zeldovich
Activate
Soot models
Kinetic model
Activate
Combustion
Emission
Formula
1
10000
200
For spray modeling some general input data such as injected fuel mass, mass flow rate, etc.
is required. Usually the standard WAVE model is used to simulate the breakup process. By
varying the characteristic breakup time via the model constant C2 calculated results can
be fitted to measurements or visualization data. For this model the droplet size has to be
set to the nozzle hole diameter (blob injection).
That only gives big droplets in the region close to the nozzle which hardly evaporate. The
effect is too less vapor in the vicinity of the nozzle which is not physical. There are two
approaches to produce some vapor close to the nozzle:
a.
2-18
Apply the child droplets breakup model which strips off mass from the initial
large droplets and generates a number of smaller droplets in the near nozzle
region. These smaller droplets are vaporized more rapidly. The child droplet
option should only be used for evaporating Diesel sprays. The stripping
mechanism is only active for droplets with Weber number larger than 50.
C1
It should be kept constant.
C2
[5.0-60] adjusts breakup to different nozzle types. C2 influences the

characteristic breakup time and hence breakup length and may vary from
one injector to another. A smaller value of C2 decreases breakup time
(breakup length) and usually decreases penetration length. 12-15 is
recommended for HD Diesel engine applications.
C3
It should usually be set to 1 to take liquid viscosity of the fuel into

account. A value of 0 (zero) will calculate breakup assuming an inviscid
liquid.
C4
[0.1-0.5] controls the number of parcels that will be initialized (the lower
the value the more new parcels).
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If C4 is too low (close to zero) too many child droplet parcels will be
created and the droplet array suffers from overflow. In this case it is
necessary to increase the value of C4 so that fewer new parcels are
created. C4 can be varied in a wide range without influencing the amount
of shed mass too much. If breakup is very slow and the parameter C4 is
close to unity it is possible that the first child droplets will be created far
downstream. To produce vapor in the vicinity of the nozzle it is necessary
to decrease C4.
C5
[0.01-0.3] gives control over the mass in the parcels (the lower the value
the less mass will be put into the child droplet parcel). Higher values of
C5 lead to an increase of vapor in the vicinity of the nozzle. The
penetration of the liquid and the vapor is hardly influenced by this
variation.
b. Apply a bimodal initial droplet size spectrum to the standard wave model (no
child breakup C4=C5=0 ). It is generally recommended that approximately
10% of the fuel droplets are injected as small droplets with a diameter of about
one order of magnitude less than the nozzle hole. These droplets are supposed
to come from the stripping process. The remaining 90% of the fuel droplets are
injected with the size of the nozzle hole.
In reality cavitation inside the nozzle reduces the effective hole diameter and
influences the primary breakup. To account for cavitation, "manually" reduce
the effective nozzle hole diameter up to 40 % as injection progresses. A time
ramp for this can be specified to account for the development of the cavitation
inside the nozzle hole.
The model WALLJET1 describes what happens if droplets hit the wall. The
angle of reflection and the droplet diameter are changed according to a
function of Weber number.
The entry controls how the domain velocity and pressure are calculated at points where a
parcel is located. This interpolation is only done for calculating spray interaction terms.
CONSTANT: Uses cellcenter values at an arbitrary point within the cell where a parcel is
located.
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Liquid
properties
Property set
Select
Diesel-1
General
settings for all
particles
Solver
2D results
Submodels
Solution Flags
Activate All
Coupling flags
Activate All, except TKE

and Dissipation
Mass balances
Activate All
Particle size
information
Activate All
Turbulent dispersion
model
Enable
Evaporation model
Dukowicz
E1
E2
Particle interaction
model
Disable
Wall interaction
model
Walljet1
Breakup model
C1
C2
C3
C4
C5
Wave
Activate particle
introduction from
nozzle
Activate
0.61
15
1
0.1
1
Particle
introduction
methods
Nozzles
NSIZES
NINTRO
NCIRCD
Nozzle[1]:
NoName
General Nozzle Data

Start
Duration
Mass
Total mass
Fluid temperature
2-20
3
3
3
714
Activate
2.975 ms
Selected
1.7286E-5 kg
350 K
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Geometry Data
Z-coordinate
Z-direction Nozzle
diameter
at holes
Spray angle delta 1
Spray angle delta 2
Circumferential hole
distribution
Spray geometry
Diagrams
Injection rate
Outer diameter
Half outer cone
angle
Particle sizes
Nozzle submodels
Nozzle flow simulation
C1
C2
C3
-0.001
1
0.00216
160
0
0
Full Spray
Table (see Figure 2-22)
0.000169
8
0.000169
Diesel Nozzle Flow
0.075
4
0
Figure 2-22: Nozzle - Diagrams - Injection Rate Table

When finished with input parameters, select Next Page to change to Simulation window.
2.3.5. Simulation
The Simulation allows the user to start the CFD simulation of the bowl fluid flow, the
injection and the combustion process.
1. Select File | Save as, specify a name, and save the Project to a location. A status bar
shows the progress, while the full FIRE Workflow Manager project is created.
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Figure 2-23: Export Project

2.
Select Start calculation wizard to open the Job Setup window as shown in the
following figure.
Figure 2-24: Job Setup Window
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Note: When defining the start parameters, the user has to consider
hardware capabilities and model size for single and parallel run. For
details refer to Chapter 6.8 of the FIRE Workflow Manager Users Guide.
3.
User functions are not required for this example. Select Start to start the simulation.
2.4. Post-Processing
During the pre-processing the user is guided through the following sections:
Analyser
Report generator
2.4.1. Analyser
The ESE Diesel Analyser allows to visualize the results obtained during the simulation of
the aerodynamics, the fuel injection and the combustion based on data stored in the *.fl2file. The results can be displayed as two-dimensional graphs. Additionally a number of
engine specific data is calculated when importing the fl2-file. This data can be displayed in
either the lower diagram of the drawing area or in tabular form.
The Analyser allows the user to perform following tasks:
Visualization of two dimensional graphs
Displaying a summary of engine specific output and graphs
1.
Select Load Results and specify the *.fl2 attached to the evaluated project.
2.
When loading is completed, the name of the file and some parameter are displayed in
the file list in the lower half of the input area. Result data is displayed in the two
diagrams of the drawing area. The upper diagram is used for common flow, spray,
species and combustion results. The lower diagram only displays Engine specific
output.
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Note: The 2D post-processing tool IMPRESS Chart can be used for

more advanced diagram comparisons and operations among curves. For
further information refer to the IMPRESS Chart Users Guide.
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Figure 2-25: ESE Diesel Analyser Window

3.
The results stored in the fl2-file reference to a Region, for which they are valid.
Related results are united in Quantity groups. Within each group any related
Quantity can be selected. The quantities are listed in alphabetical order.
4.
To display the pressure over crank angle, select the following:
5.
Region
wholeModel
Quantity group
Flow (alternatively select Combustion, Formula etc.)
Quantity
Mean pressure, Mean temperature
Refer to the following figures to show several quantities, the user should get similar
results.
Figure 2-26: Mean Pressure Output
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Figure 2-27: Mean Temperature Output

6.
In addition the simulation results can be also compared with results from
measurement. Therefore select the line with the right mouse button to open a context
menu as shown in the following figure.
Figure 2-28: Context Menu - Import Foreign Data

7.
Then select Import foreign data and specify a file with extension *.1dp or *.1dT.
Note: This file type must have the following structure (e.g. for pressure):
If a BOOST GID result file is imported pressure, temperature and rate of

heat release are loaded as native BOOST results and the user can see all
three comparisons under the corresponding sections.
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The following figures show the final state of overlapping results. Select Verification
from the relevant Region.
Figure 2-29: Comparison Simulation vs. Reference Data

9.
To create a quantity plot e.g. for equivalence ratio, change to the Quantity plots tab,
click on
to load the data as shown in the following figure (7 crank angle positions
are automatically selected 722 deg CA with maximum rate of heat release as a
central point with 3 intervals (closest FL3 record) with -10 deg Ca and +10 deg CA):
Figure 2-30: Quantity Plot Eq-T Mapping
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A relatively large number of points for crank angle positions 730, 740 and 750 deg CA in a
soot and NOx area shows a good potential for reducing the emission levels for this engines
operating point.
If IMPRESS Chart is used as the 2D post-processing tool, the results DEMO.ppd under
2D_Results in the case (DEMO) directory can be loaded and presented in a pre-defined
diagram. For further information refer to the IMPRESS Chart Users Guide.
Figure 2-31: IMPRESS Chart Diagrams
2.4.2. Report Generator

In addition to archiving the main parameters and the main results of the simulation, ESE
Diesel can generate a standard report, enabling the user to get a quick overview of the
calculated simulation results. A standard report may consist of up to four chapters: Engine
data, Mesh statistics, Engine specific output, Impress offline.
1. Locate the *.fl2 file by selecting Select fl2 file.
2. Select main sections selects which chapter should be included in the report. In
general it is suggested to activate all available options.
3. The Data step list displays all data sets available in the fl3-file of the actually analyzed
simulation. When switching to the folder Data step list, it may take some time until
the folder is displayed. This is caused by the software reading the complete result file
*.fl3, in order to find out for which data steps which quantities are available for offline
result analysis.
4. The data steps, for which two-dimensional plots should be created, must be selected by
activating the switch in front of each data step. Select a few data steps as exemplary,
CA 710.000, CA 718.000, CA 740.000.
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5. The Result data list displays all quantities available in the fl3-file of the simulation,
which is actually analyzed. The quantities, for which two-dimensional plots should be
created, must be selected by activating the switch in front of quantity. Select
exemplary for NO mass fraction, Soot mass fraction, Temperature and Spray
diameter. Note at 710 NOx and soot values are not yet in the domain.
6. The Cuts enable the user to define the cross-sections, for which two-dimensional plots
can be created. By default two Predefined cuts are defined.
7. After going through the four folders of the report generator, a report in html-format
can be created by executing Create report. After specifying a name, the report will be
created.
8. The web browser opens automatically and the result should be similar to following
figures:
Figure 2-32: Header of ESE Diesel Report
Figure 2-33: ESE Diesel Report Engine Specific Output
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Figure 2-34: ESE Diesel Report Exemplary Result at CA 718. 0
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3. ESE DIESEL 02: ESE_D / BOOST

COUPLING (927)
This chapter describes the workflow of a FIRE diesel combustion simulation using the
Engine Simulation Environment Diesel (ESE Diesel) coupled with BOOST. The required
input data for ESE Diesel and BOOST is discussed.
It is recommended that the user has a basic understanding of the FIRE Workflow Manager
Users Guide, ESE Diesel section of the CFD Tools Users Guide as well as the BOOST
Users Guide and has completed the Primer examples before beginning this example.
When using simulation tools for diesel combustion it is always necessary to perform an
adjustment of the input data for the calculation models to fit the computed results to
measurements or visualization data. This is an interactive and engine specific process,
which makes it very difficult to develop a standardized adjustment strategy.
ESE Diesel is the first CFD simulation tool, which allows beginners, intermediate users
and experts to set up, perform and analyze the injection and combustion process in diesel
engines reliably and accurately with minimum effort.
3.1. Overview
For diesel combustion simulation the calculation of the intake stroke is usually not
performed in order to reduce calculation time. This means that the calculation starts at
inlet valve closure (IVC).
A simplified geometry is used to reduce the effort for mesh generation. Details like intake
ports and valves (valve reliefs) are not considered (refer to Figure 3-1).
For a centric and rotational symmetric combustion chamber and if the fuel mass flow is
the same for all holes of the injector, only a segment of the geometry for one injected spray
can be used. The angle of the segment is given by the number of holes in the injection
nozzle (angle = 360/number of nozzle holes).
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Figure 3-1: Diesel Cake - Overview
3.2. BOOST Model

The BOOST model tcimcc.bwf (available with the BOOST installation) serves as input for
the coupling. It represents a heavy-duty 6 cylinder Diesel engine (bore = 100mm) with an
air cooler and turbo charger.
Figure 3-2: BOOST Model tcimcc.bwf
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For the ESE Diesel - BOOST coupling, the combustion model AVL MCC must be specified
in BOOST.
Figure 3-3: BOOST Combustion Model

The case is already prepared for the calculation, which can be started by clicking
Simulation | Run (BOOST v2011.1 should be used).
Note: All engine-related engine parameters are transferred from the

BOOST model to ESE Diesel. Parameters which are taken from BOOST
are shaded in ESE Diesel. Hence any engine parameter change needs to
be done in BOOST before starting the ESE Diesel session.
3.3. Start ESE Diesel Session
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Note: To set up an ESE Diesel - BOOST coupling application,

ESE Diesel v2011.1 and AWS v2011.1 must be installed.
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3.3.1. Standalone Version for Linux

1.
Open a new shell.
2.
Type the following command to start ESE Diesel standalone version:

fire_ese_diesel
3.
Or, select FIRE ESE Diesel in the AST Launcher.
3.3.2. Standalone Version for Windows

To start ESE Diesel double click on the AVL-AST icon on the desktop to open the AST
Launcher. Move the mouse over the FIRE icon to pop-up the list of programs and then
select FIRE ESE Diesel.
3.4. Pre-processing
In the Project Settings window, select BOOST coupled simulation and then click on
for Select BOOST file. Locate the file tcimcc.bwf in the BOOST_HPC sub-directory.
After selecting the file BOOST reads the input file (with the message "Waiting for BOOST
Coupling to finish") and the BOOST calculation case appears on the selection window
below. By confirming with OK a file boost_ese_data.xml is written to the directory where
the BOOST bwf file is located. The XML file contains BOOST model information to be
loaded into ESE Diesel (geometrical information, details about friction model, initial values
and boundary values for all cylinders).
Figure 3-4: Simulation based on BOOST data

The values from the BOOST model, which have been transferred to ESE Diesel are grayed
out and cannot be modified in ESE Diesel.
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3.4.1. General Data

All engine related parameters are transferred from BOOST to ESE Diesel.
Figure 3-5: BOOST Data Automatically Transferred to ESE Diesel
Note: BOOST is linked to the ESE Diesel project after loading the
BOOST .bwf file and selecting the case. This information is stored in the
ESE Diesel project file (.ese).
3.4.2. Sketcher
1.
In the Sketcher, select Create piston from template and then select template 6. No
changes are necessary under the Piston tab.
Figure 3-6: Sketcher - Bowl Specification

2.
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Under the Injector tab, the number of injector holes has been transferred from the
BOOST model and therefore is grayed out.
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Select Create injector from template and then select Injector 2. Default settings for
geometry parameters should be used.
Figure 3-7: Sketcher - Injector Specification

3.
Under the Block structure tab, the default settings are used.
4.
Under the Selections tab, select Standard selections.
3.4.3. Mesher
The Mesher contains parameters for 2D and 3D meshing. Values not specified are default.
Define the following data for 2D parameters:
Compenstion volume at
Piston
Select Generate 2D meshes. The start and end mesh for the first moving set appear in the
viewer. The 2D meshing part is finished. The user should control the list of all meshes
above the viewer if there is no star in front of the mesh set number. The small star * is
an indicator of a bad mesh.
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Figure 3-8: Mesher - 2D and 3D Parameters

Generally Export 3D meshes is selected to save the moving mesh for detailed checks in the
FIRE Workflow Manager. However for the setup of the coupling simulation it is not
necessary to save the mesh data separately since this will be done automatically when the
project is saved.
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Note: When the ESE Diesel project is saved, the mesh is stored
automatically. An essential condition is that the 2D mesh has been created.
The same file name as the project file name is assigned to the mesh.
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3.4.4. Simulation Parameters

This is used for setting various simulation parameters. This window is the same as in
FIRE Workflow Manager, therefore refer to the FIRE Workflow Manager Users Guide for
information regarding simulation parameters.
The solver specific settings are also transferred from BOOST to ESE Diesel. The file
boost_ese_data.xml, which is written to the same directory, where the BOOST BWF file is
located, contains BOOST model information to be loaded into ESE Diesel (geometrical
information, details about friction model, initial values and boundary values for all
cylinders). In addition to the XML file at the start of the coupling calculation a SSC file is
written to the FIRE case directory. The file cylinder_1_SHP.ssc contains all relevant
information concerning Start and End angle as well as information about the initial
conditions or the injection.
Thus BOOST provides all relevant information for a successful solver run, either before
the coupling calculation or during the solver run.
This is also valid for the definition in the Run mode setup. Since the parameter list is sent
to ESE Diesel after the start of the calculation any modifications made during the
simulation parameter setup in ESE Diesel will be ignored in the simulation. Values not
specified are default.
Figure 3-9: ESE Diesel Delta Crank-Angle Table Modification

The angle events and related default angle steps are defined as follows:
angle_1 = angle_SHP
angle_2 = angle_SHP
angle_3 = angle_SOI
angle_4 = angle_SOI
angle_5 = angle_SOI
angle_6 = angle_EOI
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+ 5
+ 20
- 15
- 5
- 1
+ 5
delta 1 default = 0.5

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angle_7 = angle_EOI
angle_8 = angle_EHP
+ 50

Note: The coupling calculation uses a predefined crank-angle setup. The solver
will ignore any modification of the simulation parameter specified in ESE Diesel.
Figure 3-10: Simulation Parameters before starting ESE Diesel - BOOST Coupling
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Figure 3-11: Simulation Parameters after Starting ESE Diesel - BOOST Coupling
3.4.4.1.1. Solver Control

For this example keep default settings for solver control parameters.
3.4.4.1.2. Output Control

For this example keep default settings for output to 2D and 3D-result file.
3.4.4.1.3. Modules
For this example keep default settings.
An ssc file allows specific settings in the ssf file to be changed. At the start of the
calculation FIRE automatically merges the data from the file cylinder_1_SHP.ssc with the
SSF file. Thus no parameter input is required during the setup in ESE Diesel for the fuel
injection.
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Figure 3-12: Data stored in cylinder_1_SHP.ssc file
3.4.5. Simulation
When finished with input parameters, select Next Page to change to Simulation window.
3.4.5.1. HPC (High Pressure Cycle):

In FIRE the high-pressure cycle of one cylinder is calculated. The results are transferred
(duplicated) to each cylinder on the BOOST side. In this coupling mode FIRE shows only
one case (cylinder 1).
HPC coupling
Number of BOOST cycles before coupling
30
Number of coupled cycles
Number of BOOST cycles after coupling
Select File | Save as, specify a name and save the Project to a location. A status bar shows
the progress, while the full ESE Diesel project is created.
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Figure 3-13: Export Project

When the project is saved, also the mesh is stored in the Meshes directory.
Figure 3-14: Shell Output When Project is Saved

Select Start simulation ... button to open the Job Setup window.
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hardware capabilities and model size for single and parallel run. For details
refer to Chapter 6.8 of the FIRE Workflow Manager Users Guide.
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You can leave all settings default, select Verify in order to get green check displayed left of
the Host Name and select Start to start the simulation.
Note: AWS is used to generate the required input file (.bst file) for BOOST at
the start of the coupling.
If the job is started remotely, the GUI library libXmu.so.6 must be installed on the
host. Ensure that the user has permission to the X server. For further details refer
to the main page of xhost.
After starting the simulation, the BOOST simulation will start (first 30 cycles). After that
FIRE BOOST coupling will be started. The transfer of the FIRE ROHR value for every
time step to BOOST ensures the required information exchange between the 1D and the
3D solver during the run.
3.4.5.2. Multiple High Pressure Cycle (MHPC)

The workflow is the same as in the case of HPC except that MHPC coupling should be
selected for Simulation (Figure 3-13).
In this case 6 independent cylinder directories will be generated under Calculation. The
same mesh generated previously in ESE Diesel will be used for this. After BOOST-only
simulation the simulation of cylinder number according to the firing order (defined in
BOOST) will be started.
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Figure 3-15: BOOST Simulation Control Firing Order Window

Every CFD cylinder project will be updated with the according BOOST data input after the
30 BOOST-only cycles have been finished.
3.5. Solver Run

To check the status of the calculation, the FIRE specific output (.fla) and the BOOST log
file can be used.
Open the BOOST example tcimcc.bwf. Select Simulation | Status and in the Task tab, click
on the appropriate Run option and then click on the Details icon
the file simulation.out is displayed.
. The information of
Figure 3-16: Cycle Simulation Output from BOOST
Note: Check carefully before terminating the calculation from the Status
Window. The progress of the calculation will be slower compared to a BOOST
only simulation due to the higher CPU load of the 3D simulation.
3.6. Post-processing
3.6.1. Analyser (FIRE)
The ESE Diesel Analyser allows to visualize the results obtained during the simulation of
the aerodynamics, the fuel injection and the combustion based on data stored in the *.fl2file. The results can be displayed as two-dimensional graphs. Additionally a number of
engine specific data is calculated when importing the fl2-file. This data can be displayed in
either the lower diagram of the drawing area or in tabular form.
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The Analyser allows the user to perform following tasks:
Visualization of two dimensional graphs
Displaying a summary of engine specific output and graphs
1.
Select Load Results and specify the *.fl2 attached to the evaluated project.
2.
When loading is completed, the name of the file and some parameter are displayed in
the file list in the lower half of the Input area. Result data is displayed in the diagram
of the drawing area.
Figure 3-17: ESE Diesel - Analyser Window

3.
The results stored in the fl2-file reference to a Region, for which they are valid.
Related results are united in Quantity groups. Within each group any related
Quantity can be selected. The quantities are listed in alphabetical order.
4.
To display the pressure over crank angle, select the following:

Region
whole model
Quantity group
Flow (alternatively select Comb. or Formula)
Quantity
Mean pressure, Mean temperature (ROHR)
Refer to the following figures to show several quantities, the user should get similar
results.
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Figure 3-18: Mean Pressure Output

Selected BOOST results (cylinder pressure, cylinder temperature and ROHR) can be
loaded as foreign data to the corresponding FIRE 2D results displayed in the diagram
(right mouse click on loaded File name). FIRE results have to be shifted to the last BOOST
cycle to see the effect of the FIRE input to the BOOST post-cycle simulation. FIRE results
have to be shifted accordingly to fit to the last BOOST cycle timing.
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Figure 3-19: Comparison between FIRE and BOOST post-cycle results in ESE Diesel
Analyzer
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Figure 3-20: Comparison between FIRE and BOOST coupled results in IMPRESS Chart
3.6.2. ROHR Treatment in BOOST

During the specified BOOST-only period of the simulation, the ROHR is determined by the
AVL MCC Combustion Model while in the following coupled cycles the BOOST cylinder is
running in 2-Zone Analysis mode, which means that the ROHR is derived from the
Pressure Trace calculated by FIRE. In the BOOST post-coupled cycles the analyzed (and
normalized) ROHR of the last coupled cycle is input for the applied 2-Zone Table
combustion mode.
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4. ESE AFTERTREATMENT (933)

4.1. Overview
ESE Aftertreatment is a CFD simulation tool, which allows beginners, intermediate users
and experts to set up, perform and analyze aftertreatment systems reliably and accurately
with minimum effort.
Although extremely simple to handle, online help is offered to assist the users of our
software in any situation, giving general information about the product and explaining
details useful to make use of all the capabilities of the tool.
The first example describes how the setup of the Diesel exhaust system that includes DOC
and DPF. The example only includes the pre-processing part and it is based on the
templates.
The second example describes how to import CAD surface and volume mesh and set up
SCR system.
Start ESE Aftertreatment by clicking on ESE Aftertreatment in the AST Launcher.
4.2. DOC_DPF Example - Pre-processing

The example describes the setup of the diesel exhaust system. During the pre-processing
the user is guided through the following sections:
General system data
Assembler
Mesher
4.2.1. General System Data

The General system data allows to specify general parameters of the aftertreatment line
simulated in the current project, i.e., data which is characteristic for this aftertreatment
line and therefore helps to identify it among a number of previously performed or ongoing
investigations.
In the General system data enter the names for Vehicle, Engine name and select Diesel
for Combustion system as shown in the following figure.
Figure 4-1: ESE AT General System Data

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4.2.2. Assembler
The Assembler window enables the user to assemble a complete aftertreatment line,
either by assembling individual template components or by importing a surface defining (a
portion of) the aftertreatment line or both.
icon to insert the straight pipe. In the viewer window a pipe surface
1.
Click on the
is displayed.
2.
Under the General data tab, enter the pipe parameters for StraightPipe as shown in
the following figure.
Figure 4-2: ESE AT StraightPipe: General Data

3.
Select the Inlet tab and enter the parameters shown in the following figure.
Figure 4-3: ESE AT StraightPipe: Inlet

4.
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Select the Outlet tab and click on Set to own Inlet as shown in the following figure.
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Figure 4-4: ESE AT StraightPipe: Outlet
5.
Click on the
icon to insert the next straight pipe. Enter the General data and
Outlet parameters for StraightPipe_1 as shown in the following figures. The Inlet
parameters must be the same as for the Outlet parameters for Component 1 (this is
done automatically).
Figure 4-5: ESE AT

StraightPipe_1: General Data
6.
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Figure 4-6: ESE AT StraightPipe_1: Outlet
icon to insert the catalytic converter. In the General data enter the
Click on the
length as shown in the following figure. The Cross-section parameters must be the
same as for the Outlet parameters for StraightPipe_1 (this is done automatically).
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Figure 4-7: ESE AT CAT: General Data
7.
Click on the
parameters must be the same as for the Cross-section parameters for CAT.
Figure 4-8: ESE AT StraightPipe_3:

General Data
8.
Click on the
icon to insert the bent pipe. Enter the General data parameters for
the bent pipe as shown in the following figure.
Figure 4-10: ESE AT BentPipe: General Data

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The current status in the viewer must be the same as in the following figure.
Figure 4-11: ESE AT Viewer
10. Click on the

Outlet parameters for Component 5 as shown in the following figures. The Inlet
parameters must be the same as for the Outlet parameters for BentPipe.
Figure 4-12: ESE AT

StraightPipe_4: General Data
11. Click on the

icon to insert the diesel particulate filter. Under General enter the
length as shown in the following figure. The Cross-section parameters must be the
same as for the Outlet parameters for StraightPipe_4 (this is done automatically).
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Figure 4-14: ESE AT DPF: General

12. Select the Honeycomb structure tab and modify the parameters as shown in the
following figure.
Figure 4-15: ESE AT DPF: Honeycomb Structure
13. Click on the

parameters must be the same as for the Cross-section parameters for DPF.

General Data
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14. Click on the

icon to insert the bent pipe. Enter the General data parameters for
the bent pipe as shown in the following figure.
Figure 4-18: ESE AT BentPipe_2: General Data

15. Click on the Outlet tab and modify Rotation relative to own Inlet to -180 deg.
16. Click on the
icon to insert the last component. Enter the General data
parameters for StraightPipe_7as shown in the following figure.
Figure 4-19: ESE AT StraightPipe_7: General Data

17. The final Assembler tree and surface geometry are shown in the following figure.
Figure 4-20: ESE AT Diesel Exhaust System: Surface
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4.2.3. Mesher
The Mesher window enables the user to control the meshing parameter of individual
aftertreatment components.
After switching to the Mesher, a mesh is automatically generated as shown in the following
figure.
Figure 4-21: ESE AT Diesel Exhaust System: Mesh

1.
In the Meshing Parameters window select the Resolution tab and enter the meshing
parameters shown in the following figure.
Figure 4-22: ESE AT Meshing Parameters: Resolution
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2.
Click on the
icon at Exhaust line to update the mesh with new parameters.
3.
Save the ESE AT project by selecting File | Save as. Enter Diesel_Exhaust_System
for the name and click OK.
4.
The ESE AT creates a full FIRE Workflow Manager project structure, which can be
opened in the FIRE Workflow Manager to setup and start the simulation.
Note: ESE AT is a stand alone tool which allows to setup and simulate
the complete Exhaust system.
Please refer to setup of DOC_DPF case in End_Project folder on how to

set up simulations parameters.
4.3. SCR Example Pre-processing

The example describes the setup of the SCR. During the pre-processing the user is guided
through the following sections:
General system data
Assembler
Mesher
4.3.1. General System Data

The General system data allows to specify general parameters of the aftertreatment line
simulated in the current project, i.e., data which is characteristic for this aftertreatment
line and therefore helps to identify it among a number of previously performed or ongoing
investigations.
In the General system data enter the names for Vehicle, Engine name and select Diesel
for Combustion system as shown in the following figure.
Figure 4-23: ESE AT General System Data
4.3.2. Assembler
The Assembler window enables the user to assemble a complete aftertreatment line,
either by assembling individual template components or by importing a surface defining (a
portion of) the aftertreatment line or both.
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Click on the
icon to import CAD surface of the injector component. In the import
window, locate the file SCR_Injector.flm in the Start_Data directory as shown in the
following figure.
Figure 4-24: ESE AT Define File/Scaling

2.
Click on the Define inlets/outlets tab. In the 3D viewer select the inlet edge and click
on the
icon to define the inlet side. Then click on the injector edge and select the
icon to ignore the edge. The final result is shown in the following figure.
Figure 4-25: ESE AT Define Inlets/Outlets
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Click on the Define selections tab and click on Surface under Selection types.
icon to join all surface parts. The final result is shown in the
Click on the
following figure. Then click on Import to import the surface in the Assembler.
Figure 4-26: ESE AT Define Selections

4.
Click on the
icon to import the volume mesh of the mixer component. In the
Import window, locate the file Mixer.flm in the Start_Data directory.
5.
Click on the Define inlets/outlets tab. In the 3D viewer select the inlet edge and click
on the
icon to define the inlet side. Then press Ctrl and with the left mouse
button select all inner edges on the mixer edge and select
The final result is shown in the following figure.
icon to ignore edges.
Figure 4-27: ESE AT Define Inlets/Outlets
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Click on the Define selections tab and click on Import to import the volume mesh in
the Assembler. Both components are not yet connected each component has an
anchor icon in the Assembler tree. To join both components click on the Outlet of the
SCR_Injector_1 in the assembler tree as shown in the following figure.
Figure 4-28: ESE AT Assembler Tree

icon and click OK to confirm the connection.
7.
Click on the
8.
Click on the
icon to insert the next straight pipe. Enter the General data
parameters for StraightPipe as shown in the following figure.
Figure 4-29: ESE AT StraightPipe - General Data
9.
Click on the
Outlet parameters for StraightPipe_1 as shown in the following figures.

General Data
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Outlet
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10. Click on the

icon to insert the catalytic converter. In the General data keep the
default parameters. The Cross-section parameters must be the same as for the Outlet
parameters for StraightPipe_1 (this is done automatically). The following figure
shows the current status in the Assembler tree and viewer.
Figure 4-32: ESE AT Assembler
4.3.3. Mesher
The Mesher window enables the user to control the meshing parameter of individual
aftertreatment components.
After switching to the Mesher, a mesh is automatically generated as shown in the following
figure.
Figure 4-33: ESE AT Mesher
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In the Resolution tab at the component SCR_Injector_1, click on the

icon to
define the selection for the local refinement. In the Selections definition window,
create a new selection _ref_injector around the injector region as shown in the
following figure.
Figure 4-34: ESE AT Selection Definition
2.
Click on the
figure.
icon and define the meshing parameters as shown in the following
Figure 4-35: ESE AT Edit Surface Selections
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Define 0.003 m for the Minimum cell size (component SCR_Injector_1) and activate
Preserve model details. Then click on the
shown in the following figure.
icon to update mesh. The final result is
Figure 4-36: ESE AT Meshing Parameters: Resolution

4.
Save the ESE AT project by selecting File | Save as. Enter SCR for the name and
click OK.
5.
The ESE AT creates a full FIRE Workflow Manager project structure, which can be
opened in the FIRE Workflow Manager to setup and start the simulation.
Note: ESE AT is a stand alone tool which allows to setup and simulate
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the complete Exhaust system.

Please refer to setup of SCR case in End_Project folder on how to set up
simulations parameters.
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5. ESE ENGINE (961)

This manual assumes that the user has a basic understanding of the FIRE Workflow
Manager Users Guide as well as FAME Hexa Users Guide and has completed the Primer
example before beginning this example.
The main focus of this document is to describe in a practical way the modeling of a complex
three-dimensional geometry with moving meshes by using the ESE Engine meshing tool.
ESE Engine is a tool for the automation of the meshing and moving process to setup a
moving mesh project (4-stroke engines). It is a dedicated grid generation tool for 4-stroke
gasoline and diesel engines. 2-stroke engines as well as rotary engines are not covered by
ESE Engine. For engines with pre-chamber combustion concept FAME Engine Plus
method is recommended (please refer to 920_IC_Gasoline).
5.1. Simulation Domain - Overview
Figure 5-1: Simulation Domain

Computational Domain:
The engine model, shown in Figure 5-1, can be divided into three main parts:
the intake ports, the exhaust ports and the cylinder. Each of the ports can be divided into
the valve seat region, the valve stem region and the upper port region. The cylinder is
divided into chamber, liner and piston bowl.
Engine Data:
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Bore:
80 mm
Stroke:
81.4 mm
Connecting Rod Length:
137 mm
Intake Valve Lift:
read from input file
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Exhaust Valve Lift:
read from input file
Boundary Conditions:
Intake Ports:
transient, read from input file
Exhaust Ports:
Engine Speed:

5500 Rpm
Piston Temperature:
450 K
Cylinder Liner Temperature:
450 K
Cylinder Head Temperature:
450K
Intake Port Temperature:
Problem Description:
The characteristics of the fluid system which will be modeled are as follows:
transient flow in a system with moving boundaries
to describe transient boundary conditions, input files which contain the data of the
time dependent pressure or mass flow and temperature at the system boundaries
are necessary
to control moving boundaries, input files for the valve lift will be needed
the model has to be refined in regions where gradients are expected; e.g. in the port
area, around the valves, the valve seats and in the cylinder but also around spark
plug position
the effects of the gravity are negligible and can therefore be ignored
5.2. Meshing Strategy Overview

5.2.1. Grid generation concept
The grid generation process is basically split into 3 different steps. First a moving dataset
for the valve seats and the cylinder are created using the Chamber Modeler. In a second
step static grids for the ports need to be meshed using FAME Hexa. In a final step the
moving datasets for valve seats and cylinder are assembled with the static ports using
Model Assembler.
Compared to the existing method using FAME Engine Plus (920_IC_Gasoline) for ESE
Engine is characterized by the following differences:
Only one surface model used for the entire engine cycle
Intake and exhaust ports are generated separately using FAME Hexa
Ports and cylinder connected using arbitrary interface
5.2.2. Recommended File Structure on disk

Create the following file structure on disk:
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<UserPath>/961_ESE_Engine/01_Chamber_Modeler
<UserPath>/961_ESE_Engine/02_Ports_FAMEHexa
<UserPath>/961_ESE_Engine/03_Model_Assembler
The sub-directory 01_Chamber_Modeler contains the data for the cylinder and valve seats
whereas in sub-directory 02_Ports_FAMEHexa static grids for the intake and exhaust ports
are created.
In a final step the cylinder and port models are assembled to the final moving dataset.
5.2.3. Workflow
Prepare the surface which covers both, the intake as well as the exhaust valves. If the
engine does not have valve overlap the valves can be modeled in closed position. The
liner and piston needs to be included as well. The surface must contain all valves and
ports even if not the complete engine cycle is meshed.
Note: Artificial positions are allowed which means it is not necessary for
the surface to represent the real engine position.
Figure 5-2: Surface Mesh
Define selections on the surface to identify engine components, for movement but also
for boundary conditions and initialization,.
Define edges.
Open ESE Engine Chamber Modeler and setup the project.
Start meshing process.
Create static meshes for intake and exhaust stroke in FAME Hexa.
Open ESE Engine Model Assembler and assemble cylinder model and ports.
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5.3. Surface Preparation

ESE Engine is checking the surface quality when loading to avoid problems during the grid
generation due to insufficient surface quality. The following checks are made when loading
the surface:
Check if the mesh is strictly surface mesh (without other types of cells)
Check for cracks in surface (as in FAME Surface Wrapper) with tolerance of 1e-9.
It is checked for open edges in surface which cannot be matched to some other edge
within this tolerance
Check for duplicate nodes in patches (as in FAME Surface Wrapper)
Check for sliver triangles (as in FAME Surface Wrapper) with tolerance of 1e-9. It
is checked if any height line of triangle is shorter than the tolerance (avoid very
thin triangles)
Check for identical vertices (as in FAME Surface Wrapper and in CFDWM with
tolerance of 1e-9. It is checked if any two vertices are geometrically identical (up to
tolerance)
Check for structure and orientation. This basically does 3 checks:

- Check on open edges
- Check for inconsistent neighbor patches orientation
- Check for surface flip
If the check detects critical surface input an error message is shown. In this case the
surface needs to be repaired and improved first.
Figure 5-3: Surface check (invalid surface versus correct surface input)
As shown in Figure 5-1 a surface check can help identifying problematic surfaces. The left
example (Surface_with_open_edges.flm is not part of the example) has folded patches and
lonely nodes. In total the geometry therefore consists of 3 independent regions and thus
does not fulfill the surface quality criteria. ESE Engine will inform with a message that the
surface cannot be used for grid generation and needs to be fixed first.
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Figure 5-4: Surface does not fulfill check criteria

ESE Engine requires selections for identification of engine components like the intake and
exhaust valves as well as the piston and liner.
The engine elements can be assigned automatically with the option Auto assign. This
option requires that the following selection names are available on the surface.
BND_Liner
BND_Piston
BND_Intake_valve_1
BND_Intake_valve_2
BND_Exhaust_valve_1
BND_Exhaust_valve_2
If one or more of these selections are missing an automatic assignment fails. It is also
possible to manually assign selections on the surface to the corresponding engine
components.
For movement of the respective components MOVING and BUFFER selections for the
piston and liner but also for each valve need to be defined. The moving selection need to
cover the area of the components which must follow the component movement exactly (i.e.
valve head area), whereas the buffer selection covers that regions which is used to stretch
and compress the computational domain to cover the movement.
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Note: It may reduce the effort to define engine parts if the selection
names follow the naming scheme as seen in the picture.
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Figure 5-5: Required selections on the input surface

ESE Engine needs to auto-assigning volume selections as well as face selections in the
valve seat area. The automatically created selections are called
INI_Cylinder,
INI_Intake_ports, INI_Intake_port_1, INI_Intake_port_2
INI_Exhaust_ports, INI_Exhaust_port_1, INI_Exhaust_port_2
BND_Intake_valves, BND_Intake_valve_1, BND_Intake_valve_2,
BND_Intake_seats, BND_Intake_seat_1, BND_Intake_seat_2,
BND_Exhaust_valves, BND_Exhaust_valve_1, BND_Exhaust_valve_2
BND_Exhaust_seats, BND_Exhaust_seat_1, BND_Exhaust_seat_2
It is therefore recommended that the selections defined on the input surface use the same
naming conventions. For the other surface areas any selection names can be used.
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5.3.1. Selection Naming Conventions

It is recommended to use pre-fixes for selection names for better identification, e.g.
BND_<selection name> boundary conditions
REF_<selection name> refinement selections
MOV_<selection name> selections for movement
CON_<selection name> selections for connecting edge
REM_<selection name> selections to specify removal of boundary cells
v_<selection name>
selections to create cell selection on volume mesh
Explanation of usage:
Domains bounded by selections defined as v_<selection name> on the surface are
automatically converted to cell selections on the volume mesh.
Initialization of the cylinder requires a selection on surface mesh named e.g.
v_INI_cylinder, whereas initialization of the intake and exhaust ports require a selection on
surface mesh named v_INI_Intake_ports and v_INI_Exhaust_ports. No other name should be
used for the ESE Engine grid generation using version v2011.
5.4. Edge Preparation

The edge mesh is a set of user-defined edges which are created from the discretized surface
mesh.
In ESE Engine 2 different categories of edges are used. The first category of edges is used
to create sharp edges on the volume mesh at desired locations. This is the same procedure
as known from FAME Hexa meshing approach.
Note: The amount of created edges depends on the relevant fluid

problem to be solved. The CFD software user has to pass on this
information only for those edges, which are of importance, i.e. influence the
CFD simulation result.
The second category of edges is required to create a 2D Template. For this purpose edges
need to be classified into selections.
Required edges for ESE Engine are at least the circumferential edges (typically the
outermost edge, e.g. liner or gasket) and the squish edges (if present). It is necessary to
cover the area of the cylinder and chamber area but also relevant edges for injectors and/or
spark plugs have to be defined if exists.
Since this example does not have a spark plug nor an injector the edges which are defined
are the squish edge (Blue edge) as well as the upper (Green edge) and lower cylinder
liner edge (Red edge).
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Figure 5-6: Edges input for ESE Engine Chamber Modeler
Figure 5-7: Selections on the input edges

Do NOT include edges of the valve seat or the valve heads. Edges, which are part of the
rotation symmetric part of the valve seats only need to be defined if they are not covered
by the 2D valve meshing.
Edges in the port region can either be included in the complete edge model or they can be
defined later on when the static ports are meshed using FAME Hexa.
Examples for different engine setups are shown in Figure 5-8 to Figure 5-12.
Figure 5-8: Example 1 for edge definition on chamber for gasoline engine
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Figure 5-9: Example 2 for edge definition on piston for gasoline engine
Figure 5-10: Example 3 for edge definition on piston for diesel engine
Figure 5-11: Example 4 for edge definition on chamber for diesel engine
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Figure 5-12: Example 5 for edge definition on chamber for gasoline engine
Figure 5-13: Example for edge model as it must not be defined
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5.5. Meshing Procedure ESE Engine Chamber

Modeler
5.5.1. Overview
This section describes the setup of the ESE Engine Chamber Modeler meshing procedure
including all necessary prerequisites such as selection specification, edge creation etc.
5.5.2. Create new project

The Chamber Modeler can be started from AST Launcher.
Figure 5-14: Start ESE Engine Chamber Modeler

Alternatively it can be started from a Linux shell using the command
fire_ese_engine_chamber_modeler
or on Windows command shell with
fire_ese_engine_chamber_modeler.exe
First a new ESE Engine project needs to be created. Click on Create new project (refer to
Figure 5-15) to create a new sub-directory where the ESE Engine data should be saved.
Figure 5-15: Create new ESE Engine project
5.5.2.1. Save Project

Click on the Create Folder to create a new sub-folder.
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Note: ESE Engine requires an empty folder where project data can be
stored. A warning message will be shown if the chosen directory is not
empty.
Click on the Create Folder to create a new sub-folder 01_Chamber_Modeler. Define a

name for the ESE Engine project and select Save to save the project to the following
location
<UserPath>/961_ESE_Engine/01_Chamber_Modeler
Figure 5-17: Save new ESE Engine project to sub-folder

A project structure is automatically created by ESE Engine. All meshes and settings are
saved in the 01_Chamber_Modeler folder.
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Note: To avoid inconsistent project status do NOT edit or manipulate

project data in the project folder manually.
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5.5.2.2. Import Surface Mesh

ESE Engine requires a number of input information starting with the surface and edge
mesh input, followed by the movement definition. Only if all required input is complete
ESE Engine activates the next input section.
At first only the surface section is active whereas Edges, Movement etc. is inactive and
cannot be selected.
Note: Please check the input status if the next level is not activated.
Input may be incomplete if the next level is not enabled.
Expand the project tree by clicking on

and select the surface.
. Click on the 00_Input folder in the project tree
Locate the file Surface_IV0p15mm_EV_closed_Piston_TDC.flm in:

<InstallationPath>/FIRE/v2011.1/exam/961_ESE_Engine/00_Input.
The surface mesh unit is meter. Select OK.
Figure 5-18: Surface Mesh loaded in ESE Engine GUI
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5.5.2.3. Engine Component assignment

As mentioned above, engine components need to be defined. Selections which represent the
corresponding engine components need to be assigned accordingly. Since all defined
selections follow AVLs recommended naming conventions the component assignment can
be done automatically by clicking on
Figure 5-19: Engine component Auto-assignment
Note: This manual does not explain how to create selections. All
required selections are already defined on the surface mesh.
If the selection names do not follow the recommended naming convention and Autoassignment is not possible it is possible to assign the selections manually to the
corresponding engine components.
Select the relevant selection by activating it in the Selections view from the selections list.
Add a new engine component element by selecting the corresponding engine component
and click on the right mouse button Add new element. A new engine component will be
added (i.e. Piston1). Select Piston1 from engine component list and BND_Piston from
selection list and assign the selection to the component by clicking
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Figure 5-20: Engine component assignment manually

Based on the selections ESE Engine automatically determines the corresponding valve and
cylinder axis. It therefore is required that each intake and exhaust valve is put into
separate selection.
If like shown in Figure 5-21 the selection BND_Intake_valves is assigned to the engine
component intake valve 1 the valve axis cannot be computed correctly. Whereas if each
valve is assigned as a separate engine component ESE Engine can compute the valve axis
properly (refer to Figure 5-22).
Figure 5-21: Incorrect assignment of selection to engine components
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Figure 5-22: Correct assignment of selection to engine components

Based on experience the following selections should be applied on the surface mesh:
Name
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Description of Usage
No. of
Cells/Faces
BND_Chamber
Boundary Region for Thermal BC.
5268
BND_Exhaust_ports
Thermal BC.
9555
BND_Exhaust_seats
Thermal BC at exhaust valve seats
889
BND_Exhaust_valve_1
Thermal BC at exhaust valves.
1950
BND_Exhaust_valve_2
1950
BND_Exhaust_valves
3900
BND_Inlet
Inlet BC, transient
BND_Intake_ports
Thermal BC.
BND_Intake_seats
Thermal BC at intake valve seats
948
BND_Intake_side_squish
Squish area near intake ports, used for

Thermal BC
63
BND_Intake_valve_1
Thermal BC at intake valves.
2030
BND_Intake_valve_2
2027
BND_Intake_valves
4057
BND_Liner
Thermal BC.
208
BND_Outlet
Outlet BC (exhaust valves open).
612
BND_Outlet_massflow
Outlet BC (exhaust valves closed).
612
BND_Piston
Thermal BC.
106
BND_Squish
Thermal BC.
242
MOV_Exhaust_valve_1_buffer
Specifies those cells, which are

stretched or compressed during mesh
movement (required selection for
moving procedure).
120
88
17199
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MOV_Exhaust_valve_1_moving
Moving selection for exhaust valves

(required selection for moving
procedure).).
1704
MOV_Exhaust_valve_2_buffer

moving procedure).
120
MOV_Exhaust_valve_2_moving

procedure).).
1704
MOV_Exhaust_valves_buffer

moving procedure).
248
MOV_Exhaust_valves_moving

procedure).
3408
MOV_Intake_valve_1_buffer

moving procedure).
MOV_Intake_valve_1_moving
Moving selection for intake valves

procedure).).
MOV_Intake_valve_2_buffer

moving procedure).
MOV_Intake_valve_2_moving

procedure).).
MOV_Intake_valves_buffer

moving procedure).
MOV_Intake_valves_moving

procedure).).
3968
MOV_Piston_buffer

moving procedure).
208
MOV_Piston_moving
Moving selection for piston head

procedure).).
106
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1984
43
1984
89
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_REF_Exhaust_valve_guides
Refinement selection (will not be

assigned to volume mesh).
2738
_REF_Intake_valve_guides
Refinement selection (will not be

assigned to volume mesh).
1806
_REM_Intake_ports_split
Cells intersected with this selection

will be removed (will not be assigned
to volume mesh).
382
v_INI_Cylinder
Domain for cylinder initialization.
5799
v_INI_Exhaust_ports
Domain for exhaust port initialization.
11056
v_INI_Intake_ports
Domain for intake port initialization.
18235
Table 5-1: Selections on Cylinder Mesh
5.5.3. Edge Mesh

After the surface input has been completed the next input section is enabled automatically.
Select the Edge menu in the menu bar on the left side (refer to Figure 5-23) to switch to
edge model input section.
Figure 5-23: Edge mesh input section in menu bar

and select the edge model.
. Click on the 00_Input folder in the project tree
Locate the file Edges_IV0p15mm_EV_closed_Piston_TDC.flm in:

The edge mesh unit is meter. Select OK.
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Figure 5-24: Load edge mesh
5.5.3.1. Characteristic Edges

In addition to the edges which are required to create sharp edges on the volume mesh
characteristic edges are used for setting up a 2D mesh for the cylinder.
It is necessary to assign the selections defined on the edge mesh to the corresponding
characteristic edges. ESE Engine at least requires a cylindrical edge for the 2D template to
be able to create a cylinder template. For the circular edge it is possible to assign either the
selection circular or the selection piston.
Add a new characteristic edge element for the Circular edge by clicking first on the
Circular edge and then on the right mouse button. This opens the option Add new
element. Click Add new element. A new characteristic edge element circular_edge_1 is
created in the Characteristic Edges list. Select circular_edge_1 in the Characteristic Edges
list and circular from selection list and assign the selection to the list by clicking
Add a second characteristic edge element for the Squish edge by clicking first on the
Squish edge and then on the right mouse button to Add new element. A new
characteristic edge element squish_edge_1 will be added. Select squish_edge_1 from the
Characteristic Edges list and circular from selection list and assign the selection to the list
by clicking
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Figure 5-25: Characteristic edges
5.5.4. Movement
After all engine components are defined and the surface and the edge model is specified the
Movement module in the workflow bar becomes active.
In this section the movement of the different engine components needs to be defined. The
setup of valve and piston movement for the relevant moving part is valid for the entire
engine cycle.
The procedure is described exemplary for one moving part piston and intake valve 1. All
other moving parts have to be specified in the same way.
The global parameter which needs to be defined first is whether the loaded surface
represents a real engine position or if this is a virtual surface. The loaded input surface
has closed exhaust valves, the intake valves are open 0.15mm and the piston is at TDC.
This configuration represents the engine position at 360 CA and thus it would be possible
to select Engine position and set the Surface crank angle to 360. However to demonstrate
how a virtual surface position is set up the Virtual position is selected.
Figure 5-26: Virtual surface position option
5.5.4.1. Movement Piston
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1.
Click on Piston1 and check that the option Moving is activated.
2.
The type of movement is already pre-defined and should be set to PDF movement.
3.
Enter the input values for the connecting rod. The value is 137mm.
4.
The input value for the pin offset is 0 and therefore no action is necessary.
5.
Enter the input values for the stroke. The value is 81.4mm.
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6.
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The Movement and Buffer selection is automatically filled in by ESE Engine.
Note: If the AVL naming conventions are used ESE Engine supports
auto-fill in for moving and buffer selection.
In case of Virtual position is chosen ESE Engine expects the piston at TDC position.
Since the piston is at TDC the axis offset is 0. If the piston in the surface would be placed
at BDC the axis offset would be 81.4mm.
Figure 5-27: Movement definition for the piston
5.5.4.2. Movement valves

1.
Click on intake_valve_1 and check that the option Moving is activated.
2.
An infinite thin gap cannot be resolved in CFD simulation and thus it is necessary to
define a point at which a valve should open and close. The position at which the valve
should be treated as closed is defined with the option Closed at. Enter the input
values for the closed valve lift value. The valve should be treated as closed at 0.15mm.
This corresponds to an opening range from 360 CA to 582 CA. Before 360 CA and
after 582 CA the intake valves are closed.
Set the Closed at value to 0.15mm.
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Figure 5-28: Intake valve lift curve at valve open

3.

tree and select the edge model.
. Click on the 00_Input folder in the project
A filter allows a .dat-file or .txt-file to be imported. This ASCII file must contain two
columns: the first column describes the crank-angle and the second column the
displacement.
Locate these files in
- intake_valve.dat
Note: The valve lift curve must be defined from 0CA to 720 CA. Start
and end valve must be identical. The curve must not be constant at the
Closed at value. The valve lift curve must not have negative values.
Figure 5-29: Supported and not supported valve lift shape
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8.
The lift curve unit is meter.
9.
The Movement and Buffer selection is automatically filled in by ESE Engine.
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Note: If the AVL naming conventions are used ESE Engine supports
auto-fill in for moving and buffer selection.
10. In case of virtual position of the engine ESE Engine expects the valves at fully closed
position. The intake valves are already 0.15mm open in the input surface and therefore
Axis offset needs to be set to 0.15mm.
Figure 5-30: Setup Intake valve movement

11. The exhaust valves are completely closed in the input surface and therefore Axis offset
needs to be set to 0.0mm.
Figure 5-31: Setup Exhaust valve movement
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When input for intake and exhaust valves is made automatically the time line at the bottom of
the ESE Engine GUI is updated to visualize the opening and closing period of the valves.
While the Grey bar indicates that the valve is closed the White bar shows the valve opening
period.
Figure 5-32: Valve opening visualized in Time Line
5.5.5. Port Connection

Click on Port Connection in the Menu bar to move to the next input section. The port
connection defines the border between the part which is handled by the ESE Engine
Chamber Modeler and the intake and exhaust ports generated with FAME Hexa.
In the ESE Engine viewer the valve is positioned at half max. valve lift. The green line
corresponds to the moving selection MOV_Intake_valve_1_moving and the red color
correlates with the buffer selection defined in the movement section.
Move the Blue nodes downwards to the rotation symmetric part of the intake seats as
shown in Figure 5-33.
Figure 5-33: Port connection setup for intake valve 1
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Figure 5-34: Port connection setup for intake valve 1 (detailed view)
Although the port connection line basically can have any inclination it is recommended to
have the inner and outer nodes rather horizontal. This is advantageous for the valve
movement. In any case extreme inclination as shown in Figure 5-35 should be avoided.
Figure 5-35: Port connection setup as it should not be defined

The number of Port subdivisions is 24 for all 4 valves.
The setup from intake valve 1 can be copied to the intake valve 2. Select intake_valve_1
and click right mouse button Copy. Change to intake_valve_2 and click again right mouse
button and Paste the setup to the intake valve 2.
For the exhaust valves proceed the same way as for the intake valves. Move the Blue
nodes downwards to the rotation symmetric part of the exhaust seats and copy the setup
from exhaust valve 1 to exhaust valve 2.
Figure 5-36: Port connection setup for exhaust valves

With the setup of the Port connection the global input definition is completed.
Note: Any change of the setup for surface, edges, movement and/or the
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port connection will invalidate existing datasets and thus changing of one or
more of those parameters will cause a reset of the project status. Already
completed datasets will be reset and require rerun of the grid generation
steps.
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5.5.6. Decoupled ports

By default ports are considered only during the period when valves are open. During the
closed valve period the ports are eliminated and thus not considered in the computational
domain.
In case that the ports should not be included when the valves are closed this chapter can be
entirely skipped. However this input section can be processed at any time later during the
ESE Engine grid generation process but must be finished before the components are
assembled in Model Assembler if decoupled ports should be included after all.
Note: Omitting the exhaust and intake ports when the valves are closed
will decrease the model size and thus will help to minimize calculation
turnaround time.
For some applications (i.e. heat transfer analysis) the closed intake and exhaust ports can be
included. To consider the closed ports a 2D block topology for the upper section of the valve
seats need to be set up. The definition is a global input which is valid for the entire engine
cycle.
Click in the first row to get to intake_valve_1.
1.
Set the Valve seat subdivision to 20
2.
Set the Port subdivisions to 24
3.
Set the Valve gap interpolation to linear.
4.
Set the Circumferential subdivisions to 64
5.
Click
to confirm the input.
Arrange the topology block by dragging the Blue nodes using the left mouse button. The
figure below will help finding the right setup.
Figure 5-37: Adaption of topology for intake valve 1

When a valid 2D mesh is created the Yellow bar or Red bar left to the valve is changed to
Green.
After the intake valve 1 has been set up the configuration can be assigned to the intake
valve 2. Select intake_valve_1 and copy the setup using the right mouse button and click
Copy. Change to intake_valve_2 and paste the configuration using the right mouse button
and select Paste. All settings from intake valve 1 will be transferred to intake valve 2.
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Click in the third row to get to the exhaust_valve_1.

1. Set the Valve seat subdivision to 20
2.
3.
Set the Valve gap interpolation to linear.
4.
Set the Circumferential subdivisions to 64
5.
Click
Arrange the topology block by dragging the Blue nodes. After the exhaust valve 1 has
been set up copy the configuration to exhaust valve 2.
Figure 5-38: Decoupled ports - exhaust seat topology
5.6. Meshing Procedure

5.6.1. Create first dataset from 360 to 390
The Time line at the bottom of the GUI is used to organize the datasets that are required to
cover the desired range of the engine cycle.
In a newly generated project the time line is empty. Once the movement parameters are
defined, the crank angle ranges where a valve is closed are marked grey.
Figure 5-39: Empty Time Line
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Figure 5-40: Valve opening visualized in Time Line
In the following steps datasets have to be created to fill the Time line for the relevant crank
angle range. If a full engine cycle simulation is done datasets from 0 CA to 720 CA have to
be defined.
Each dataset covers independent setups for valves and cylinder meshes. The setup can be
different between datasets. The setup is mainly dependent on the engine geometry, the valve
timing and the valve and piston position.
To set up a first dataset move the mouse cursor to the timeline and click the right mouse
button. An option Insert will open. Click Insert to create a new dataset.
Figure 5-41: Create dataset from 360CA to 390 CA

1.
Set the Mesh point at 370 CA
2.
Set the Lower value to 360 CA
3.
Set the Upper value to 390 CA
4.
Click OK to confirm the input.
Datasets cannot cross the opening / closing point of a valve since these points enforce a
mandatory topology change. ESE Engine automatically checks that you create a dataset in
the valid region.
Figure 5-42: New dataset from 360CA to 390 CA

A yellow bar marks the defined dataset range from 360 CA to 390 CA. The dashed line
marks the Mesh point at 370 CA. ESE Engine allows working directly in the time line but one
also can still work in the menu bar on the left side.
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It is recommended to complete one dataset before creating a new one (vertical progress in
time line). But it is also possible to make first all meshes for intake valve 1 from 0 CA to 720
CA (horizontal progress in time line). The second approach might be successful only if all
parameters are already known (i.e. setup known from a similar engine or variant).
5.6.1.1. Valve
Click in the first row of the newly generated dataset to get to Valve Meshing, or choose the
workflow step Valve in the menu bar.
ESE Engine automatically selects intake_valve_1 and generates a first default valve seat
topology. It automatically detects that the intake valve is open and offers open valve topology
only.
to confirm the
6.
Set the Open valve topology to 6 blocks unstructured and click

input. The topology in the viewer will change.
7.
8.
Set the Port edge subdivisions to 15
9.
Set the Port edge interpolation to Progressive. The factor is 0.2 and Propagate to
opposite is activated.
10. Set the Valve seat interpolation to Progressive. The factor is 5 and Propagate to
11. Set the Valve seat buffer subdivisions to 10.
12. Set the Valve seat subdivisions to 12.
13. Set the Cylinder buffer subdivisions to 7.
14. Set the Valve gap subdivisions to 12.
15. Set the Valve gap interpolation to Progressive symmetric. The factor is 5 and
Propagate to opposite is activated.
16. Set the Circumferential subdivisions to 64.
17. Click
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Figure 5-43: 2D valve seat mesh at 370 CA
When a valid 2D mesh is created the Yellow bar in the time line is changed to Green
visualizing that a valid mesh has been created.
ESE Engine allows checking the quality of the 2D valve mesh not only at the meshing position
but also at 360 CA and 390 CA. To do that one can toggle between the 3 different viewer
modes on the right upper side of the ESE Engine viewer.
shows the 2D valve seat at the mesh point (370 CA), whereas
shows the minimum
position (in this case valve seat at 360 CA) and

shows maximum valve position (in this
case valve seat at 390 CA). The target is to find a proper setup for the valve seat topology
which allows mesh movement for the entire dataset range from 360 CA to 390 CA.
. The valve position at 360 CA
Change the viewer to the minimum position clicking on
will be shown. Arrange the topology blocks by dragging the Blue nodes using the left mouse
button. The figure below will help finding the right setup for the block topology. The middle
block corner can only be moved in the Meshing position
Figure 5-44: Adaption of topology @ 360 CA

ESE Engine automatically follows the contour of the valve and seat based on a default
snapping criteria. If flow relevant corners are not covered automatically it is possible to
enforce snapping to those corners by inserting additional markers.
Insert a new marker using the right mouse button. The mouse cursor has to be positioned
near the respective corner (refer to Figure 5-45).
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Figure 5-45: Insert a new marker at the valve corner
After the intake valve 1 has been set up the configuration can be assigned to the intake valve
2. Select intake_valve_1 and copy the setup using the right mouse button and click Copy.
Change to intake_valve_2 and paste the configuration using the right mouse button and
select Paste. All settings from intake valve 1 will be transferred to intake valve 2.
Figure 5-46: Copy settings from intake valve 1

In the next step the exhaust valves are set up. Click in the third row of the generated dataset
to get to the exhaust valve 1, or choose the workflow step Valve exhaust_valve_1 in the
menu bar.
ESE Engine automatically detects that the exhaust valve is closed and changes settings area
accordingly.
Note: ESE Engine checks the status of the valves (open/closed) according
to the input definition.
1.
Set the Closed valve topology to Single block and click
2.
Set the Valve seat subdivisions to 3.
3.
Set the Valve gap subdivisions to 3.
4.
Set the Valve gap interpolation to Linear.
5.
Set the Circumferential subdivisions to 64.
6.
Click
7.
Arrange the topology block by dragging the right upper Blue node using the left
mouse button. The two right nodes should be rather vertical aligned
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Figure 5-47: 2D exhaust valve seat mesh at 370 CA

Finally the 2D valve topology should look like shown in Figure 5-48.
Figure 5-48: 2D intake valve seat mesh at 370 CA

8. Copy the setup from exhaust valve 1 to exhaust valve 2.
Examples for insufficient setup can be found in Figure 5-49. It does not show all possible
problems but gives an extract of incorrect setup.
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Figure 5-49: Incorrect setup of 2D valve topology
5.6.1.2. 2D template
Click in the row for 2D template of the newly generated dataset to get to 2D template
meshing, or choose the workflow step 2D template in the menu bar.
Figure 5-50: Choose 2D template section either in Time line or via menu bar
ESE Engine generates a 2D mesh for the cross sectional area of the cylinder automatically.
The input for this grid is the subdivision of the 2D valve seat and the edges defined in the
input section.
1.
Set the Point redistribution center to Cylinder.
2.
Set the Valve projection direction to Valve and Cylinder.
3.
Select intake_valve_1
4.
Set the Number of boundary layers to 6.
5.
Set the Total boundary layer thickness to 0.0012m.
6.
Set the Compression ratio to 1.
7.
Copy the setup from intake_valve_1 using right mouse button Copy.
8.
Select intake_valve_2 and paste the setup from intake_valve_1 using right mouse
button Paste.
9.
Select exhaust_valve_1
10. Set the Number of boundary layers to 4.

11. Set the Total boundary layer thickness to 0.0006m.
12. Set the Compression ratio to 1.
13. Copy the setup from exhaust_valve_1 using right mouse button Copy.
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14. Select exhaust_valve_2 and paste the setup from exhaust_valve_1 using right mouse
button Paste.
15. Click
Finally the 2D template should look like shown in figure below. The status bar in the
timeline will change to Green.
Figure 5-51: 2D template
Note: 2D template meshing will only work if a circular edge is defined in

the input definitions. Check input data carefully.
5.6.1.2.1. Hints for 2D template setup

It is important that at least a circular edge is defined in the Input definition. If this input is
missing the 2D meshing will fail with an error message.
Figure 5-52: Error message if input is missing

The circular edge is a required input for the 2D paving step and defines the outer boarder
for the paver. It does not matter whether the circular and the squish edge (if exists) are at
the same vertical height. ESE Engine projects all defined characteristic edges into a single
plane for paving.
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Figure 5-53: Circular edge definition missing

As a consequence, if 2D paving is started without a circular edge defined, paving will fail.
The correct definition of the edge input is shown in Figure 5-54. The selection name is not
an issue and can be chosen freely. For better understanding in this example the selection
names have been chosen according to their purpose. Alternatively also the selection piston
could be assigned to the Characteristic Edges as circular edge.
Figure 5-54: Correct setup of circular edge definition

If the paving fails the dataset is set to semi-transparent mode which indicates that the
dataset is still locked and cannot be modified. If the dataset remains locked due to the
problem with 2D template meshing it is necessary to break the lock.
Select the dataset which is locked and break the lock using the right mouse button Break
lock.
Figure 5-55: Break lock option on right mouse button
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Note: Use the option Break lock only if it is clear that no other process is
active on the dataset. Unjustified deactivation of the lock can damage the
dataset.
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Defining a characteristic edge in the category Squish Edge allows generating a more
geometry fitted 2D template. This feature is recommended for all gasoline engines with squish
areas in the combustion chamber but is not used on diesel engines since they have a flat
cylinder head.
An example of the 2D template with and without the consideration of a squish edge is shown
in Figure 5-56.
Figure 5-56: 2D template w/o (left side) and with (right side) squish edge
In the next step the 2D template is extruded along the cylinder axis to generate a 3D
template. The 3D template will be used as a start topology to create the mesh for the cylinder.
During the extrusion of the 2D template the layers are adjusted automatically in order to fit the
start topology to the shape and tilting of the intake and exhaust valves.
Figure 5-57: 3D template structure (schematic description)

As shown in Figure 5-57 the 3D template is divided in 3 blocks. The block AB (above Blue
layer) which is above the valve seat, the block BC (from Green layer to Blue layer)
managing the layer adjustment from planar to valve fitted orientation and finally the block CD.
This block is the linear extruded block (from Red layer to Green layer).
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In this work step the correct positioning of the blocks and its block boarders is done.
Note: The right setup of the 3D template is the most crucial work step. A
proper configuration will pay for itself in terms of grid quality and
movement capabilities.
Click in the row for 3D template of the newly generated dataset to get to 3D template set
up, or choose the workflow step 3D template and Set up in the menu bar.
In the first step the global 3D Template Settings valid for both intake and both exhaust
valves need to be defined.
1.
Set the Subdivision AB to 20.
2.
Set the Subdivision BC to 35.
3.
Set the Subdivision CD to 5
The 3D viewer shows the plane cut through the intake_valve_1. Each of the black lines is a
simple representation of the 2D template (projected view).
Figure 5-58: 3D template after setting subdivisions for AB, BC and CD

Layers which are crossing the squish area like shown in Figure 5-58 will cause stair like
topology in this region (refer to Figure 5-59). With such a configuration the grid quality of
the final grid is sorely afflicted. It either has poor grid quality (like shown in Figure 5-59)
or even can have negative volumes and thus could not be used for a solver run. The poor
grid quality in those areas is further on known as a limiting factor later on during mesh
movement. That means even when the gird at the Mesh point could be used for a solver
run the movement (deformation) of such a mesh might be limited or even impossible.
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Figure 5-59: Unfavorable 3D template configuration

The block borders can be adjusted by moving the Blue points A, B, C and D in order to
improve the 3D topology. The points can be moved horizontally (shrinking/expanding the
start topology) or vertically (layer orientation/inclination).
4.
Move the Blue point B vertically as shown in Figure 5-60. The cross-hair cursor
position in Figure 5-61 can be used for a more accurate adjustment. In this dataset the
point B should be placed as far as the layer 31 is just beneath the squish. If another
layer is the closest correct the vertical position of the point B accordingly.
Figure 5-60: Adjustment of point B
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Figure 5-61: Layer alignment after moving point B upwards

For better understanding how the layer alignment improved the grid quality the start
topology as well as the final grid for the variant with vertically moved point B is shown
below.
Figure 5-62: Recommended 3D template configuration

Point A, C and D do not have to be moved for this dataset.
5.
Edge constrains is a feature which allows connecting layers to Characteristic Edges

which have been specified in the input definition. Layers associated with the
Characteristic Edges follow the contour of those edges and hence the resulting start
topology will have a rather high congruence with the CAD model at those areas.
The layer which is closest to the cylinder edge should be defined first. If the previous
steps (1 to 4) have been set up according to the manual the closest layer is 31.
Move the mouse cursor to the layer 31. The selected layer will be highlighted as shown
in Figure 5-63.
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Figure 5-63: Selected layer is highlighted

Click on the right mouse button to open the Characteristic Edges options. Assign the
layer to the Characteristic Edge circular (circular_edge_1).
Figure 5-64: Click to assign layer to circular edge

Select the layer 31 again and tick off the second Characteristic Edge squish
(squish_edge_1).
Figure 5-65: Layer successfully assigned to characteristic edges

The layer index as well as the destination name is listed in the Edge Constrains table
on the left side (refer to Figure 5-64).
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Figure 5-66: Edge Constraints table
Note: If the block nodes (A, B, C and D) are moved and/or the number of
sub-divisions for those blocks (AB, BD and CD) is changed it is necessary to
adjust the layers in the edge constraints table accordingly.
It is recommended to move the layer rather close to the surface to have a clear
position for the meshing process in the next step. If the neighboring layer is closer to
the surface it might again create stair-like structure. In Figure 5-67 it can be clearly
seen that on the left side layer 31 is closer to the chamber surface. But due to the
inclination of the layers on the right side (where layer numbers are placed) already
layer number 32 is closer to the surface.
Figure 5-67: Not favorable setup of edge constraints

Moving point B slightly upwards improved the setup significantly as shown in Figure
5-68. In this setup the layer 31 is always closer to the surface than the layer 32.
Figure 5-68: Recommended setup of edge constraints

6.
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Activate the option Remove blocks above squish.
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7.
Activate the option Use RBF.
8.
Valve specific settings

Settings defined in point 1 to 7 are global settings and valid for this dataset
independent on the valve. The valve specific settings to be defined are found in the
table below. Use Copy/Paste (right mouse button) to transfer settings from one valve
to another.
intake_valve_1
Angle
Thickness
No. of connecting
intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
10
10
10
10
0.0001
0.0001
0.0001
0.0001
layers
No. of radial connecting
layers
No. of upper valve
layers
Upper valve layer
thickness
9.
Click
To generate the 3D start topology select Generation in the menu bar. Click
the grid generation.
to start
Figure 5-69: Start 3D template generation
Note: The grid generation process can take some minutes. The amount of
time for this step depends usually on the hardware.
The status bar in the timeline will change to Green. The mesh checks info menu left to
the 3D viewer provides summary information about the generated grid.
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Figure 5-70: 3D start topology
5.6.1.4. 3D mesh
The start topology set up in chapter 1.6.1.3 will now be used to generate the 3D volume
grid.
Click in the row for 3D mesh of the active dataset (timeline) to get to 3D mesh, or choose
the workflow step 3D mesh in the menu bar.
Click
to start the grid generation.
This is again a CPU intensive step and might take some minutes to finish. The status bar
in the timeline will change to Green. The mesh checks info menu left to the 3D viewer
provides summary information about the generated grid.
Figure 5-71: 3D mesh generation finished
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Note: An inappropriate start topology can extend the grid generation

process significantly.
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5.6.1.5. Mesh movement

ESE Engine is doing that step fully automatically. It is only necessary to define the mesh
movement increments for forward and backward movement.
Click in the row for Mesh movement of the active dataset in the time line to get to Mesh
movement. Or choose the workflow step Mesh movement and Setup in the menu bar.
1. Set the Mesh movement forward increment to 10.
2. Set the Mesh movement backward increment to 10.
3. Automatic treatment of cylinder layers is deactivated
4. Click
Figure 5-72: Mesh movement setup

During the mesh movement process detailed information about the status is given in the
progress window as well as in the message/logging area. The progress window provides an
overview about the data sets already done or currently in progress. In the message/logging
area at the bottom of the ESE Engine GUI messages can be filtered by message type.
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Figure 5-73: Mesh movement progress window
Figure 5-74: Mesh movement message/logging area

In the time line detailed information about the result of mesh movement is given. The Green
bar in Mesh movement indicates that the moved positions (360CA, 380 CA and 390 CA)
have been successfully created. All moved meshes passed the mesh quality check and are
ready to be used for a solver run.
The little bar beneath the Mesh movement bar provides information about the mesh quality
between the created positions. A so called Dummy run is done automatically during the
mesh movement step and the interpolated mesh positions are checked. The Green bar
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shows that the movement for the entire dataset can be done and the meshes passed the
mesh quality.
Figure 5-75: Dataset completed

This dataset can be used for a solver run. For detailed checks click Mesh movement and
Generation in the menu bar. Selecting one of the created positions 360CA, 370 CA (is the
mesh point), 380 CA and 390 CA show details about the dummy run and the number of
interpolation layers used in this setup.
To load any position between 360CA and 390CA select the corresponding crank angle
position out of the list (see Figure 5-76).
By default in the viewer the model is shown shaded with wires. This mode can be also
activated by clicking in the viewer bar on
. If bad cells are found in the generated mesh
they can be visualized changing the display option to flat shading by clicking
in the viewer
bar. Now only bad cells are shown with wires while the other cells are displayed in shaded
mode.
Figure 5-76: Detailed summary information for each mesh position
5.6.2. Create dataset from 550 to 582

To minimize grid generation effort ESE Engine allows copying or mirroring of created
datasets. It makes use of engine characteristics like the fact that a typical valve lift curve is
symmetric (valve opens and valve closes again).
To mirror the dataset select the dataset 360 CA to 390 CA in the timeline and click the
right mouse button. An option Mirror over will open. Click on one of the two intake valves
in the list to mirror the dataset. A new dataset is created at the intake valve closing
position.
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Figure 5-77: Mirror dataset about intake valve 1

Select the just created dataset and click the right mouse button. An option list will open.
Select Modify to enter the modify option for this dataset and change the setup.
Figure 5-78: Dataset range at intake valve closing
To mirror the dataset select the dataset 360 CA to 390 CA in the timeline and click the right
mouse button. An option Mirror over will open. Click on one of the two intake valves in the list
to mirror the dataset.

1. Set the Mesh point at 570 CA
2. Set the Lower value to 550 CA
3. Set the Upper value to 582 CA
4. Click OK to confirm the input.
A warning message will appear. It informs that the modifications will invalidate the setup
and it will reset the dataset. Since no meshes have been created so far for this dataset we
can accept. Click
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Figure 5-80: Warning message
5.6.2.1. Valve
Click in the first row of the mirrored dataset to get to Valve Meshing, or choose the workflow
step Valve in the menu bar.
All settings have been copied from the reference dataset. Since the Mesh point has been
changed slightly it is recommended to check the position of the topology nodes (Blue nodes)
carefully. The nodes are geometrically transferred and thus can be positioned slightly
different.
2 nodes need to be adaped according to Figure 5-81.
Figure 5-81: Correct block corners in 2D valve mesh

Select intake_valve_1 and copy the setup using the right mouse button and click Copy.
Change to intake_valve_2 and paste the configuration using the right mouse button and click
Paste. All settings from intake valve 1 will be transferred to intake valve 2.
Repeat the steps for the exhaust valves. Check the node positions on the closed exhaust
valve and correct them. Copy the configuration from exhaust_valve_1 to exhaust_valve_2.
Click in the row for 2D template of the dataset to get to 2D template meshing, or choose the
workflow step 2D template in the menu bar.
No additional modification is necessary all data can directly be taken from the mirrored
dataset.
Click in the row for 3D template of the dataset to get to 3D template set up, or choose the
workflow step 3D template and Set up in the menu bar.
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All settings from the dataset 360 CA to 390 CA have been copied to this dataset. Thus
only some modifications are necessary to consider the new piston position.
1.
2.
3.
Set the Subdivision CD to 60 and change the interpolation method from Linear to
Progressive symmetric with factor 5.
4.
Activate the option Remove blocks above squish
5.
Activate the option Use RBF
6.
Assign layer 82 to edge constraints squish (squish_edge_1) and circular

(circular_edge_1)
intake_valve_1
Angle
Thickness
No. of connecting
intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
10
10
10
10
0.0001
0.0001
0.0001
0.0001
layers
layers
No. of upper valve
layers
Upper valve layer
thickness
7. Click
to start
5.6.2.3. 3D mesh
Click

1. Set the Mesh movement forward increment to 10
2. Set the Mesh movement backward increment to 10.
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4. Click
Figure 5-82: Dataset 550 CA to 582 CA

To set up a the next dataset move the mouse cursor to the timeline just after the dataset 360
CA to 390 CA and click the right mouse button. An option Insert will open. Click Insert to
create a new dataset.

1.
2.
3.
4.
5.6.3.1. Valve
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1. Set the Open valve topology to 4 blocks structured and click

The topology in the viewer will change.
2.
Set the Port edge subdivision to 20
3.
Set the Port edge interpolation to Progressive symmetric. The factor is 5 and
4.
Set the Valve seat buffer subdivisions to 8.
5.
6.
Set the Cylinder buffer subdivisions to 5.
7.
8.
Set the Valve gap interpolation to Progressive symmetric. The factor is 5 and
9.
10. Click
11. Arrange the topology blocks by dragging the Blue nodes using the left mouse button.
The figure below will help finding the right setup for the block topology.
12. Insert two new markers at the valve contour using the right mouse button. The mouse
cursor has to be positioned near the respective corner. (refer to Figure 5-84).
Figure 5-84: Insert a new marker at the valve corner

The final 2D valve structure for the minimum, the mesh point and the maximum position
for this dataset is shown in Figure 5-85.
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Figure 5-85: 2D valve seat mesh at 390 CA, 420 CA and 470 CA
When a valid 2D mesh is created the Yellow bar in the time line is changed to Green.
After the intake valve 1 has been set up copy configuration to intake valve 2. Select
intake_valve_1 and copy the setup using the right mouse button and click Copy. Change to
intake_valve_2 and paste the configuration using the right mouse button and click Paste.
Click in the third row of the generated dataset to get to the exhaust valve 1, or choose the
workflow step Valve exhaust_valve_1 in the menu bar.
1. Set the Closed valve topology to Single block and click
2.
3.
4.
5.
6.
Click
7.
mouse button. The two right nodes should be rather vertical aligned.
8.
Copy the setup from exhaust valve 1 to exhaust valve 2.
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1.
2.
3.
4.
5.
6.
7.
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8.
button Paste.
9.

12. Set the Compression ratio to 1.
button Paste.
15. Click
1.
2.
3.
Set the Subdivision CD to 20.
4.
Move the Blue point B vertically as shown in Figure 5-86. The cross-hair cursor can
be used for a more accurate adjustment. In this dataset the point B should be placed
as far as the layer 64 is just beneath the squish.

5.
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Move the mouse cursor to the layer 64. The selected layer will be highlighted as shown
in Figure 5-87.
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Figure 5-87: Selected layer is highlighted

6.
7.
(squish_edge_1).
8.
9.
10. Valve specific settings

intake_valve_1
Angle
Thickness
No. of connecting
intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
layers
layers
No. of upper valve
layers
Upper valve layer
thickness
11. Click
The final start topology configuration is found in Figure 5-88.
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Figure 5-88: 3D start topology configuration

to start
5.6.3.4. 3D mesh
Click

1.
Set the Mesh movement forward increment to 25.
2.
Set the Mesh movement backward increment to 15.
3.
Automatic treatment of cylinder layers is deactivated.
4.
Open the Advanced options sub-folder.
5.
Set Piston layer (-1 for auto detect) to -1 (default).
6.
Set Chamber layer (-1 to turn off) to -1 (default).
7.
Use RBF must be activated (default).
8.
Set RBF factor to 0.5 (default).
9.
Set Laurent poly. degree to 16 (default).
10. Set Max. num valve interpolation layers to 17.
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11. Set Interpolation check delta to 0.5 (default)

12. Special cylinder wall treatment must be activated (default).
13. Click
Figure 5-89: Mesh movement - Advanced options
5.6.3.5.1. Mesh interpolation (Max. num valve interpolation layer)

Cells attached to the piston or valve surface have an exact movement definition. They
either move with the valve motion or the piston lift. Basically all cells are interpolated with
PDF method. If the intake and/or exhaust valves are open a certain area around the valves
is interpolated according to the valve lift. Several layers around the valves are used to
gradually change the interpolation from valve specific interpolation factors to piston
specific interpolation. A larger number of interpolation layers will increase this region and
thus result in a smoother change between these 2 methods.
The advanced option Max. num valve interpolation layers allows changing the number of
layers which are used for smoothing between piston and valve interpolation. The default
value is 7.
The value 0 disables interpolation using the valve lift curve and all interpolation is done
with the piston movement (PDF) only whereas the value equal to or greater than 1 enables
the valves surfaces for valve lift curve interpolation. Any value greater than 1 defines the
maximum number of layers around the valve that is interpolated using a combination of
the valve lift curves and the piston movement.
The program automatically chooses the value with the best results within the given range.
Figure 5-90 shows a simplified description of the different layer groups in the cylinder. The
piston layers are not overlapping with the valve layers and the mesh is featured by good
grid quality.
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Figure 5-90: Simplified description of the interpolation layers in the cylinder without
overlapping layers
However this setup is dependent on the relative speed between the different layer regions.
If for example the intake valve accelerates much faster than the piston (or vice versa) and
the number of layers beneath the valve are very dense packed the interpolation range is
limited.
Figure 5-91: Simplified description of the interpolation layers in the cylinder with
overlapping layers
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Note: The layers around the valves are onion-like arranged around the
valve contour and may not correspond to the layers defined in 3D template.
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ESE Engine allows setting the number of layers connected to the valve movement and is
found in the advanced options. The default value for the option Max. num valve
interpolation layers is 7.
During the mesh movement step automatically as many dummy runs are done as Max.
num valve interpolation layers is defined. ESE Engine automatically finds out how many
layers should be connected to the valve in order to get valid meshes during movement.
Figure 5-92: Mesh interpolation information
Note: Increasing the number of valve interpolation layers will increase

number of dummy runs done during the mesh movement. This will slightly
influence the grid generation time since more dummy runs are done. Keep
the number of interpolation layers small.

This dataset can be mirrored again about the intake valve lift curve. To mirror the dataset
select the dataset 390 CA to 470 CA in the timeline and click the right mouse button. An
option Mirror over will open. Click on one of the two intake valves in the list to mirror the
dataset.
Note: The copy feature operates on the discretized valve lift curve which
might create some interpolation inaccuracies.
A warning message informs that the dataset needs to be cropped. Click

confirm.
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Figure 5-93:
A new dataset is created filling the remaining gap in the time line of the intake stroke.
1.
2.
3.
4.
can accept. Click
to confirm.
5.6.4.1. Valve
All settings have been copied from the reference dataset. Since the Mesh point has been
changed slightly it is recommended to check the position of the topology nodes (Blue nodes)
carefully. The nodes are geometrically transferred and thus can be positioned slightly
different. Check the block nodes whether they need to be corrected.
If a correction is necessary the setup needs to be copied to intake valve 2. Repeat the steps
for the exhaust valves.
Note: The more the value for the Mesh point is changed after the Mirror
step the more likely the block nodes need to be adapted.
Click in the row for 2D template of the dataset to get to 2D template meshing, or choose the
workflow step 2D template in the menu bar.
dataset.
only some modifications are necessary to consider the new piston position.
8.
9.
10. Set the Subdivision CD to 40 and change the interpolation method from Linear to
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11. Activate the option Remove blocks above squish

12. Activate the option Use RBF
13. Assign layer 84 to edge constraints squish (squish_edge_1) and circular
(circular_edge_1)
intake_valve_1
Angle
Thickness
No. of connecting
intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
layers
layers
No. of upper valve
layers
Upper valve layer
thickness
14. Click
to start
5.6.4.4. 3D mesh
Click

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1.
2.
3.
4.
5.
6.
7.
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8.
9.

11. Set Interpolation check delta to 0.5 (default).
13. Click
The grid generation for the intake stroke is completed. The next step is to create meshes
for the compression stroke.

The datasets for compression stroke can either be started from intake valve close or from
TDC position. Following the engine motion the dataset from intake valve closing is created
first.
To set up the dataset move the mouse cursor to the timeline just after the dataset 550 CA to
582 CA and click the right mouse button. An option Insert will open. Click Insert to create a
new dataset.
1.
2.
3.
4.
During the compression stroke ESE Engine takes advantage from another engine
characteristic. The datasets which are created for compression stroke are mirrored to the
expansion stroke automatically if pin offset is 0.
In the time line the mirrored dataset is displayed with Light Blue color. The dataset from
expansion stroke is linked to the dataset from the compression stroke. If modifications are
made on the compression stroke dataset the expansion stroke is changed automatically,
too.
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Figure 5-94: Dataset from compression stroke mirrored to expansion stroke
5.6.5.1. Valve
1.
2.
3.
4.
5.
6.
Click
7.
8.
Copy the setup from exhaust valve 1 to intake valve 2.
1.
2.
3.
4.
5.
6.
Click
7.
8.
Copy the setup from exhaust valve 1 to exhaust valve 2.
Figure 5-95: 2D valve seat topology for closed valves
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1.
2.
3.
4.
5.
6.
7.
8.
button Paste.
9.
Select exhaust_valve_1 and paste the setup from intake_valve_1 using right mouse
button Paste.
10. Select exhaust_valve_2 and paste the setup from intake_valve_1 using right mouse
button Paste.
11. Click
1.
2.
3.
4.
Move the Blue point B vertically. The cross-hair cursor position in Figure 5-96 can be
used for a more accurate adjustment. In this dataset the point B should be placed as
far as the layer 61 is just beneath the squish.
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5.
6.
7.

(circular_edge_1)
intake_valve_1
Angle
Thickness
No. of connecting
intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
layers
layers
No. of upper valve
layers
Upper valve layer
thickness
8. Click
to start
5.6.5.4. 3D mesh
Click

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1.
2.
3.
4.
Click
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To set up a the dataset move the mouse cursor to the timeline just after the dataset 582 CA
to 660 CA and click the right mouse button. An option Insert will open. Click Insert to create
a new dataset.
1.
2.
3.
4.
In the time line the new dataset as well as the mirrored dataset is created.
5.6.6.1. Valve
1.
2.
3.
4.
5.
6.
Click
7.
8.
Copy the setup from exhaust valve 1 to intake valve 2.
9.

12. Set the Valve gap interpolation to Linear.
14. Click
15. Arrange the topology block by dragging the right upper Blue node using the left
16. Copy the setup from exhaust valve 1 to exhaust valve 2.
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Figure 5-97: 2D valve seat topology for closed valves
1.
2.
3.
4.
5.
6.
7.
8.
button Paste.
9.
button Paste.
button Paste.
11. Click
In addition to the Valve specific settings it is possible to define a local refinement. The
refinement mode can be activated using the corresponding button in the viewer controls
area.
If no refinements were defined the Viewer directly switches to the refinement definition
mode. Define a polygon to mark the area that is to be refined using the left mouse button.
End the definition of the refinement area using the right mouse button.
The refinement gets executed using the Apply button.
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Figure 5-98: Activate local refinement in 2D template

to confirm
Mark a polygon area according to Figure 5-99for local refinement. Click
the input. The 2D template will be re-meshed considering the local refinement inside the
marked polygon.
Figure 5-99: Define local refinement in 2D template

Use the right mouse button over an area that is not already defined to add additional
refinement areas (if some refinements were already defined).Or use the right mouse button
over an area that is already defined to delete a local refinement. A list of options will open.
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Figure 5-100: Options for local refinement in 2D template after first refinement is
defined
Note: Please check the status of the refinement mode button in the viewer
controls area. If the button is not activated local refinement cannot be
defined.
1.
2.
3.
4.
Move the Blue point B vertically. The cross-hair cursor position in Figure 5-101 can
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5.
6.
7.

(circular_edge_1)
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intake_valve_1
Angle
Thickness
No. of connecting
intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
layers
layers
No. of upper valve
layers
Upper valve layer
thickness
8. Click
to start
Figure 5-102: 3D start topology with local refinement around spark location
5.6.6.4. 3D mesh
Click
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1.
2.
Set the Mesh movement backward increment to 30
3.
4.
Click
5.6.7. Create dataset from 60 to 144.2

The dataset from intake valve closing to 660 CA is automatically mirrored to the
expansion stroke which corresponds to the dataset range from 60 CA to 138CA. Typically
the exhaust valve opening starts at a different crank angle position in the expansion stroke
than the intake valve closes in the compression stroke.
The mirrored dataset therefore needs to be extended to cover the crank angle range from
60 CA to 144.2 CA which corresponds to the exhaust valve opening position (exhaust
valve is 0.15mm open).
Move the mouse cursor to the dataset 60 CA to 138 CA and right click in the marked
area. Chose Detach to disconnect this dataset from the one in the compression stroke.
Figure 5-103: Detach dataset

Detaching the dataset takes some time since all data from valve mesh to Mesh movement is
mirrored and saved to disk.
When the dataset is detached move the mouse cursor to the dataset 60 CA to 138 CA and
right click to Modify the dataset. Change the upper valve to 144.2 CA and click
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Figure 5-104: Modify dataset upper value

All data from Valve meshing till 3D mesh directly can be taken and does not have to be remeshed.
The only step to be re-done is the Mesh movement step since the upper limit had to be
adjusted.
1. Set the Mesh movement forward increment to 30.
2. Set the Mesh movement backward increment to 30
3. Automatic treatment of cylinder layers is deactivated.
4. Click
The grid generation for the compression/expansion stroke is completed. The final step is to
create meshes for the exhaust stroke.

The first dataset of the exhaust stroke could be set up either at exhaust valve opening or at
exhaust valve closing. Both steps would be basically possible.
However it is recommended to start with exhaust valve closing position. The distance
between the valves and the piston is smaller at exhaust valve closing compared to exhaust
valve opening event and thus might be more critical to set up.
Note: Set up the more critical dataset first and mirror afterwards to the
less sensitive engine position. The more sensitive dataset is expected at
those positions where valves and piston have lower distance.
To set up a the first dataset at exhaust stroke move the mouse cursor to the timeline just
before the dataset 360 CA to 390 CA and click the right mouse button. An option Insert will
open. Click Insert to create a new dataset.
1.
2.
3.
4.
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Figure 5-105: Dataset range at exhaust valve closing
5.6.8.1. Valve
1.
2.
3.
4.
5.
6.
Click
7.
8.
Copy the setup from intake valve 1 to intake valve 2.
to confirm the
1.
Set the Open valve topology to 6 blocks unstructured and click

2.
3.
Set the Port edge subdivisions to 15
4.
Set the Port edge interpolation to Progressive. The factor is 0.2 and Propagate to
5.
Set the Valve seat interpolation to Progressive. The factor is 5 and Propagate to
6.
Set the Valve seat buffer subdivisions to 10.
7.
8.
Set the Cylinder buffer subdivisions to 7.
9.
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12. Click
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Figure 5-106: Adjustment of block corners for exhaust valve closing

When a valid 2D mesh is created the Yellow bar in the time line is changed to Green.
1.
2.
3.
4.
5.
6.
7.
8.
button Paste.
9.

button Paste.
14. Click
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1.
2.
3.
4.
Move the Blue point B vertically as shown in Figure 5-107. The cross-hair cursor
position in that figure can be used for a more accurate adjustment. In this dataset the
point B and C should be adjusted so that the layer 85 is just beneath the squish.

5.
Move the mouse cursor to the layer 35. The selected layer will be highlighted.
6.
7.
(squish_edge_1).
8.
9.
10. Valve specific settings

intake_valve_1
Angle
Thickness
No. of connecting
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intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
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layers
0.0001
0.0001
0.0001
0.0001
layers
No. of upper valve
layers
Upper valve layer
thickness
11. Click
to start
5.6.8.4. 3D mesh
Click in the row for 3D mesh of the active dataset (time line) to get to 3D mesh, or choose
Click

1.
Set the Mesh movement forward increment to 5
2.

4. Click
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Figure 5-108: Project status after movement of dataset 330 CA 360 CA
5.6.9. Create dataset from 144.2 to 180

This dataset can be mirrored about the exhaust valve lift curve. Select the dataset 330 CA
to 360 CA and right click in the marked area. An option Mirror over will open. Click on
one of the two exhaust valves in the list to mirror the dataset. A new dataset is created at
the exhaust valve closing position.
1.
2.
Set the Lower value to 144.2 CA
3.
4.
Click
A warning message will appear. The mirrored dataset automatically found the mesh point
at 163.56 CA and the upper limit is set to 178.28 CA. This unusual crank angle positions
have been adjusted to 165 CA and 180 CA respectively.
It informs that the modifications will invalidate the setup and it will reset the dataset.
Since no meshes have been created so far for this dataset we can accept. Click
confirm.
to
5.6.9.1. Valve
Since the Mesh point has been changed slightly it is recommended to check the position of
the topology nodes (Blue nodes). The block corners of both closed intake valves will already
be at right position and thus do not need to be corrected.
The exhaust valve position is slightly different since valve moves slightly between 163.56 CA
and 165 CA. As a consequence the block corner at the most outer exhaust valve diameter
position needs to be adjusted slightly.
Select exhaust_valve_1 check node positions and adjust the position.
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Copy the setup to exhaust_valve_2 using the right mouse button and click Copy. Change
to exhaust_valve_2 and paste the configuration using the right mouse button and click
Paste.
Click in the row for 2D template to get to 2D template meshing, or choose the workflow step
2D template in the menu bar.
dataset.
only some modifications are necessary to consider the new piston position
1.
2.
Progressive with factor 5.
3.

(circular_edge_1)
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Figure 5-110: 3D template layout for dataset 144.2 CA to 180 CA

4.

intake_valve_1
Angle
Thickness
No. of connecting
intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
layers
layers
No. of upper valve
layers
Upper valve layer
thickness
5. Click
to start
5.6.9.4. 3D mesh
Click
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1.
2.
3.
4.
Click
5.6.10. Create dataset from 254 CA to 330 CA

To set up a the next dataset move the mouse cursor to the timeline just before the dataset
330 CA to 360 CA and click the right mouse button. An option Insert will open. Click Insert
to create a new dataset.

1.
2.
3.
4.
5.6.10.1. Valve
1.
2.
3.
4.
5.
6.
Click
7.
8.
Copy the setup from intake valve 1 to intake valve 2.
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9.
Set the Open valve topology to 4 blocks structured and click

to confirm the
10. Set the Port edge subdivision to 20.

11. Set the Valve seat interpolation to Progressive Symmetric. The factor is 5 and
12. Set the Valve seat buffer subdivisions to 8.
14. Set the Cylinder buffer subdivisions to 5.
18. Click
Figure 5-112: Adjustment of block corners for exhaust valve
5-80
1.
2.
3.
4.
5.
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6.
7.
8.
button Paste.
9.
button Paste.
button Paste.
11. Click
1.
2.
3.
4.
Move the Blue point B vertically. The cross-hair cursor position in Figure 5-113 can

5.
Move the mouse cursor to the layer 70. Click on the right mouse button to open the
Characteristic Edges options. Assign the layer to the Characteristic Edge circular
(circular_edge_1). Select the layer 64 again and tick off the second Characteristic
Edge squish (squish_edge_1).
6.
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7.
8.

intake_valve_1
Angle
Thickness
No. of connecting
intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
0.0001
layers
layers
No. of upper valve
layers
Upper valve layer
thickness
9. Click
to start
Figure 5-114: 3D template for dataset 254 CA - 330 CA
5.6.10.4. 3D mesh
Click
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1.
2.
3.
4.
5.
6.
7.
8.
9.

11. Set Interpolation check delta to 0.5 (default).
13. Click
Figure 5-115: Moved dataset 254 CA to 330 CA

This dataset can be mirrored again about the intake valve lift curve. To mirror the dataset
select the dataset 254 CA to 330 CA in the timeline and click the right mouse button. An
option Mirror over will open. Click on one of the two intake valves in the list to mirror the
dataset.
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A warning message informs that the dataset needs to be cropped. Click

confirm.
to
Figure 5-116: Warning message that dataset will be cropped

A new dataset is created filling the remaining gap in the time line of the intake stroke.
1.
2.
3.
4.
can accept. Click
to confirm.
5.6.11.1. Valve
Since the Mesh point has been changed slightly it is recommended to check the position of
the topology nodes (Blue nodes). The block corners of both closed intake valves will already
be at right position and thus do not need to be corrected.
The exhaust valve position is slightly different. As a consequence the block corner at the most
outer exhaust valve diameter position needs to be adjusted slightly.
Select exhaust_valve_1 check node positions and adjust the position.
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Copy the setup to exhaust_valve_2 using the right mouse button and click Copy. Change
to exhaust_valve_2 and paste the configuration using the right mouse button and click
Paste.
Click in the row for 2D template to get to 2D template meshing, or choose the workflow step
2D template in the menu bar.
dataset.
only some modifications are necessary to consider the new piston position
1.
Set the Subdivision CD to 40 and keep the interpolation method Progressive

Symmetric with factor 5.
2.

(circular_edge_1)
3.

intake_valve_1
Angle
Thickness
No. of connecting
intake_valve_2
exhaust_valve_
exhaust_valve_
0.0001
0.0001
0.0001
0.0001
layers
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0.0001
0.0001
0.0001
0.0001
layers
No. of upper valve
layers
Upper valve layer
thickness
4. Click
Figure 5-118: 3D template layout for dataset 180 CA to 254 CA

to start
5.6.11.4. 3D mesh
Click

5-86
1.
2.
3.
4.
Click
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Figure 5-119: Moved dataset 180 CA to 254 CA

With the last dataset the entire engine cycle has been done. From 0 CA to 720 CA all
meshes for the intake valve seats, the exhaust valve seats as well as for the cylinder
domain has been successfully generated.
The status is also reflected in the time line of ESE Engine. All dataset have valid meshes
and can be used for a solver run.
Note: If one or more datasets are marked Red, or dark Green check the
results and input settings for those datasets. Datasets which are marked
Red have to be corrected to get valid meshes. Datasets which are marked
Dark Green might be used for a solver run but should be checked first.
An example for problems during mesh movement is shown in Figure 5-120. The movement
in opening direction from 370 CA to 390 CA works without problems. Therefore the
movement status bar is colored Green.
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Figure 5-120: According to status mesh movement needs to be checked

For the movement back to 360 CA ESE Engine cannot find a valid configuration with
layers connected to the intake valve. ESE Engine automatically will take 0 layers if the
mesh check provides a valid result. If the number of interpolation layers is set to 0 all
components would be interpolated with PDF function.
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Note: PDF interpolation during intake and exhaust stroke should be

combined with small movement steps (i.e. 5 CA) in order to avoid
interpolation error on intake and exhaust valves.
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5.7. Ports
After all datasets for the moving valve seat and cylinder region have been created static
intake ports and exhaust ports have to be created. Basically different tools could be used to
generate a static mesh. The probably most convenient way to generate the ports is using
AVLs automatic grid generation tool FAME Hexa.
5.7.1. Port Connection export

The surface and edges input for FAME Hexa grid generation can be exported in ESE
Engine. Select the Port connection menu in the menu bar on the left side (refer to Figure
5-121).
A surface for the intake and exhaust port is automatically saved. The valve position of the
respective valves corresponds to a valve position at half maximum valve lift. The data is
exported to the folder
<UserPath>/961_ESE_Engine/01_Chamber_Modeler/port/
Figure 5-121: Port connection export

The files are called:
Cut__surface__0.flm
Cut__surface__1.flm
Cut__edge__0.flm
Cut__edge__1.flm
With that final step all necessary works steps in ESE Engine Chamber Modeler have been
completed and the tool can be closed. Select File and Quit to close the tool.
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Figure 5-122: Close ESE Engine Chamber Modeler

The grid generation can be done directly in this sub-directory. However for more neatly
arranged data structure parallel to the folder 01_Chamber_Modeler a new directory
02_Ports_FAMEHexa is created.
Copy the just created surfaces and edges (Cut__surface__0.flm, Cut__surface__1.flm,
Cut__edge__0.flm and Cut__edge__1.flm) to the new folder.
5.7.2. Edge and Surface Preparation

Open CFDWM and import the created surfaces and edges from the folder
02_Ports_FAMEHexa.
The intake and the exhaust ports are meshed separately. It is recommended to rotate the
intake and the exhaust ports to the effect that the intake and the exhaust valve axis are
orientated parallel to cylinder axis. This intermediate step ensures proper grid quality at
the connection to the seats created with ESE Engine.
Note: High grid quality of the FAME Hexa grid in general and at the
connection to the valve seats in particular will guarantee a stable solver
run.
Rotate the intake port -19.5 about the X-axis as shown in Figure 5-123.
Figure 5-123: Rotate intake port surface and edge model

Define flow relevant edges at the intake flange as well as at the valve guide. Save the surface
as well as the edges to the folder
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Figure 5-124: Edge and surface model for intake port

Selections are automatically saved within the export step in ESE Engine Chamber
Modeler. It is possible to add additional selections depending on the respective needs.
However for the final assembly step ESE Engine requires specific selections which must
not be removed from the surface.
Note: Do not remove selections which are automatically created by ES

Engine. It will negative affect further actions and will cause misoperation.
Figure 5-125: Selections on the intake port surface

Rotate the exhaust port 22 about the X-axis. Define flow relevant edges at the exhaust
flange as well as at the valve guide. Save the surface as well as the edges to the folder
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Figure 5-126: Edge and surface model for intake port
5.7.1. Create mesh for intake and exhaust ports

The static ports are generated with FAME Hexa. The tool can be started from AST
Launcher.
Figure 5-127: Start ESE Engine Chamber Modeler

FAMEHexaGUI
prepared for this example.
. Select the settings file which is already
Locate the file Intake_ports_conf.fgs in:
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<InstallationPath>/FIRE/v2011.1/exam/961_ESE_Engine/02_Ports_FAMEHexa
Figure 5-128: Load FAME Hexa settings for the intake ports
Note: The settings file implies that the surface is rotated -19.5 about xaxis.
Replace the surface and edge input in the FAME Hexa GUI with the data of your project
and start mesh generation by clicking on Start in the menu bar. Click
grid generation.
to start the
Figure 5-129: Start FAME Hexa grid generations

prepared for this example.
. Select the settings file which is already
Locate the file Exhaust_ports_conf.fgs in:

<InstallationPath>/FIRE/v2011.1/exam/961_ESE_Engine/02_Ports_FAMEHexa
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Figure 5-130: Load FAME Hexa settings for the exhaust ports
Note: The settings file implies that the surface is rotated -22 about x-axis.
Replace the surface and edge input in the FAME Hexa GUI with the data of your project
and start mesh generation by clicking on Start in the menu bar. Click
grid generation.
to start the
5.7.1. Transfer intake and exhaust ports back

In a final step the intake and exhaust ports need to be rotated back to their original
position.
Load the just created intake and exhaust meshes in CFDWM. Rotate the intake port 19.5
and the exhaust port about -22 about x-axis.
Figure 5-131: Rotate ports back to original position
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Figure 5-132: Static intake and exhaust ports generated with FAME Hexa
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Note: The cell size on both sides of the arbitrary connections should
feature similar size. Big differences might affect simulation accuracy
negatively
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5.8. Assembly
5.8.1. Overview
The meshes created with ESE Engine Chamber Modeler and the static ports created with
FAME Hexa are merged in a final assembly step to moving mesh dataset that can be used
for a solver run. The output will be a <filename>.flm and <filename>.fmo set.
5.8.2. Create new project

The Model Assembler can be started from AST Launcher.
Figure 5-133: Start ESE Engine Model Assembler

fire_ese_engine_modler_assembler
fire_ese_engine_ modler_assembler.exe
5.8.3. Load Chamber Modeler project

At first the ESE Engine Chamber Modeler project is loaded. Click on ESE Engine project
in the menu bar and expand the project tree by clicking on
project file from the 01_Chamber_Modeler folder.
. Open the ESE Engine
Locate the file 961_ESE_Engine.eseice in:

<UserPath>/961_ESE_Engine/01_Chamber_Modeler.
Click
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Figure 5-134: Open ESE Engine Chamber Modeler project

After the project is loaded in the Model Assembler the active range is shown together with
the surface for easy identification.
Figure 5-135: Open ESE Engine Chamber Modeler project
5.8.4. Load Volume meshes

Click on Volume meshes in the menu bar to add the static intake and exhaust port
meshes. To add volume meshes click
to open the file selection box. Open the static
intake port mesh from the 02_Ports_FAMEHexa folder.
Locate the file Intake_ports.flm in:
<UserPath>/961_ESE_Engine/02_Ports_FAMEHexa.
Click
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Figure 5-136: Load intake port mesh

to open the file selection box. Open the static exhaust
To add the exhaust ports click
port mesh from the 02_Ports_FAMEHexa folder.
Locate the file Exhaust_ports.flm in:
<UserPath>/961_ESE_Engine/02_Ports_FAMEHexa.
Click
The loaded intake and exhaust ports are displayed in the 3D viewer in the Model Assembler.
The validity of the input can be checked both from the list in the table and also visually in the
3D viewer. While in the table the file name and the path to the loaded file are listed in the 3D
viewer the correct placement of the volume meshes can be checked.
In Figure 5-137 an example for correct placement of intake and export is shown. Both volume
meshes are exactly matching with the chamber mesh. If a wrong volume mesh would be
loaded, like demonstrated in Figure 5-138, it would show up immediately.
Figure 5-137: Correctly loaded volume meshes
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Figure 5-138: Wrong placed volume meshes

The ports are added to the cylinder domain during the valve opening period. However the
ports can be included also when the valves are closed. To consider the ports when valves are
closed tick off the field Decoupled ports for both port (refer to Figure 5-139).
Figure 5-139: Activate decoupled ports
5.8.5. Assemble and output

To specify the output file path as well as the target file name click on Output in the menu
bar and expand the project tree by clicking on
5-140) to create a new sub-folder.
. Click on Create Folder (refer to Figure
Figure 5-140: Create new ESE Engine Model Assembler folder
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Define a name for the ESE Engine Model Assembler folder.

<UserPath>/961_ESE_Engine/03_Model_Assembler
Define a name for the Output FMO file.
Click on Save to confirm the input.

Click Run assembler to start the assembly process. The ESE Engine Model Assembler
loads one dataset after another and connects the static intake and exhaust ports
accordingly. Before the ports can be connected they are moved to the corresponding
positions.
This work step is processed fully automatically and will take some minutes to finish.
During the assembly process detailed information about the status is provided. The
progress window provides an overview about the data sets already done or currently in
progress. In the message/logging area at the bottom of the Model Assembler GUI messages
can be filtered by message type.
Figure 5-142: Model assembling process status information
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In addition to the moving mesh dataset (.flm and .fmo) a message file
<filename>_results.txt is created at the end of the assembly process. The file contains
detailed check information for each mesh position. The file can be loaded when the
assembling has been finished by clicking on
Figure 5-143: Check information written to <filename>_results.txt file
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5.9. Check list for grid generation

Before starting the grid generation the following checks should be made to reduce
problems. The list is not exhaustive but can give a quick overview about known sources of
problems.
Surface:
Only the flow relevant area is covered (wetted surface).
The mesh is strictly a surface mesh.
Intake, exhaust and piston are covered within one surface.
It consists of only 1 independent region.
The surface features rotation symmetric valve seats.
The surface orientation is consistent.
Surface has no open edges.
The surface has no lonely nodes, duplicate nodes, identical vertices or folded patches.
Selections to identify the engine components are available.
Selections for movement of valves and piston are available.
Selections for initialization and to set boundary conditions are defined. They follow
the required naming conventions (INI_Cylinder, INI_Intake_ports,
INI_Exhaust_ports, BND_Intake_valves, BND_Exhaust_valves, )
Edges:
The edge model matches with the surface model.
Only the flow relevant edges have been defined.
Edges which are automatically covered by the 2D valve meshing are not part of the
edge mesh.
The edge mesh has no duplicate elements.
Selections for the characteristic edge mesh setup (circular) are defined.
The edge designated for use as circular edge is a closed edge type.
Valve lift curve:

The valve lift curve is defined from 0 to 720.
The value at the start and the end is identical.
The curve is given in ASCII format featuring 2 columns (angle and valve lift).
Headers and/or footers may not be in the valve lift curves.
The curve has no negative values.
The valve lift is not constant at the Closed at values.
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Own issues:
_____________________________________________________________________
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If the check list has been passed successfully the grid generation can be started.
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5.10. Mesh preparation for solver run

Typically at the inlet and outlet flange either mass flow or pressure conditions are
prescribed. The selected boundary type is used during the entire solver run.
In this example at the inlet (intake port flange) mass flow rate and at the outlet (exhaust
port flange) a combination of static pressure and mass flow rate is prescribed. All boundary
traces are cycle resolved and cover the entire engine cycle.
If only static pressure is used at exhaust port flange chapter 5.10.1 can be skipped. A
method to change the boundary type within a solver run is described in.
5.10.1. Change outlet boundary type during solver run

To use static pressure during the exhaust stroke and mass flow during the intake as well
as the combustion stroke two separate selections BND_Outlet (for static pressure) and
BND_Outlet_massflow (for mass flow) have to be defined. The mesh created within this
tutorial (961_ESE_Engine.flm) has both selections.
During the exhaust stroke (from 142CA to 360CA) the pressure boundary conditions
shall be applied. As a consequence the selection BND_Outlet has to contain all faces at the
exhaust port flange and the selection BND_Outlet_massflow must not include any faces.
Therefore the selection BND_Outlet_massflow has to be cleared.
For all other datasets all faces from the selection BND_Outlet need to be eliminated and
only the selection BND_Outlet_massflow should contain the faces of exhaust port flange.
Open FMO Editor in CFDWM and load the moving mesh data set 961_ESE_Engine.fmo.
Figure 5-144: Moving mesh loaded in FMO Editor
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To load the first data set (0.0-60.0) click

. Open the selection menu for the
loaded mesh Selection_Change_0 to modify the selection BND_Outlet. Remove all faces
assigned to this selections by clicking
(refer to Figure 5-145).
After the selection has been modified save the mesh back to the moving dataset. Repeat
this step for dataset 40.0-144.2, 360.0-390.0, 390.0-470.0, 470.0-550.0, 550.0-582.0, 582.0660.0 and finally for 660.0-720.0.
For the datasets covering the exhaust stoke (144.2CA- 360CA) the faces from the
selection BND_Outlet_massflow have to be removed.
Figure 5-145: Clear selection BND_Outlet
5.10.1. Exhaust valve opening

At exhaust valve opening the decoupled exhaust ports get connected with the cylinder
domain. For this added cells usually values are copied from the neighboring area which
was already available before the rezone.
In order to guarantee a smooth gradient between the high pressure level in the cylinder
and the lower one in the exhaust ports it is recommended to smooth the added section.
Figure 5-146: Exhaust valve seat before (left) and at valve opening (right) @ 144.2CA
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This additional smoothing step gains in importance when pressure drop between exhaust
ports and cylinder rises.
A new cell selection needs to be added as shown in Figure 5-147. Open FMO Editor in
CFDWM and load the moving mesh data set 961_ESE_Engine.fmo.
. Open the selection menu for the
Select the data set 144.2-180.0 and click
loaded mesh Selection_Change_0 and add a new cell selection as shown in Figure 5-147
and Figure 5-148.
Figure 5-147: Add cell selection at exhaust valve seats
Figure 5-148: Valve gap region without (left) and with (right) smoothing @EVO
After the selection has been created save the mesh back to the moving dataset by clicking
Save Mesh.
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5.11. Solver GUI

The calculation setup described in this chapter is based on the configuration including the
ports when the intake and exhaust valves are closed. This means that the ports are
included in the computational domain during the entire engine cycle.
5.11.1. Typical Boundary Conditions

Inlet and outlet boundaries
In order to describe transient boundary conditions, input files which contain the data of
the time dependent pressure (mass flow) and temperature at the system boundaries are
necessary.
Wall boundaries
Prescribed values for wall boundaries are also taken from measurements or based on
experience.
The following regions are summarized in
Table 5-2: Wall Boundary Regions
Region
Wall treatment
Movement
Piston
Prescribed temperature
Moving wall
Liner
Fixed wall
Cylinder head
Fixed wall
Intake valves
Moving wall
Exhaust valves
Moving wall
Intake ports
Fixed wall
Exhaust ports
Fixed wall
5.11.2. Define Data for Calculation

In the project tree, select the Calculation folder with the right mouse button and then
select New Case / 961_ESE_Engine.
A new Case folder is created where all necessary data for the solver and post-processing
are stored.
Select Solver Steering File and select Edit SSF from the submenu.
Enter the following input values for this example (values not specified are default):
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5.11.2.1. Run Mode

Run mode
Crank_angle
Delta_alpha
Table
upto crank-angle
deg
DeltaAlpha
upto 640
upto 760
upto 864
upto 865
upto 1080
1
0.2
1
0.2
1
Start angle
360
deg
End angle
1080
deg
Speed
5500
1/min
5.11.2.2. Module Activation

Select Species transport and Combustion.
5.11.2.3. Boundary Conditions

In the Boundary conditions folder in the parameter tree, select BC[1]: NoName to access
the following input fields:
BND_Inlet
Sel. for BC
BND_Inlet
Name of BC
BND_Inlet
Type of BC
Inlet/Outlet
Inlet/Outlet
Mass Flow
Massflow
Table Import: inlet_massF_kgs.dat
kg/s
Fixed temperature
Table Import:
inlet_temp.dat
Fixed turbulence
Yes
Turb. ref. Velocity
% of mean velocity =
Turb. kin. energy =
0
0
1
Turb. length scale =

0.001
% of hydraulic diameter and Turb. diss.
rate are calculated from Turb. kin.
energy and Turb. length scale.
m/s
m/s
m
Insert a new boundary condition by selecting Boundary conditions in the parameter tree
with the right mouse button and selecting BC: Insert from the submenu.
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Select BC[2]: NoName to access the following input fields:

BND_Outlet_
massflow
Sel. for BC
BND_Outlet_massflow
Name of BC
BND_Outlet_massflow
Type of BC
Inlet/Outlet
Inlet/Outlet
Mass Flow
Pressure
Table Import:
outlet_massF.dat
EGR mass
fraction
Fixed temperature
No
Fixed scalar
No
Fixed turbulence
No
Pa
BND_Outlet
Sel. for BC
BND_Outlet
Name of BC
BND_Outlet
Type of BC
Inlet/Outlet
Inlet/Outlet
Static Pressure
Pressure
Table Import:
out_StatP.dat
EGR mass
fraction
Fixed temperature
No
Fixed scalar
No
Fixed turbulence
No
Pa
BND_Chamber
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Sel. for BC
BND_Chamber
Name of BC
BND_Chamber
Type of BC
Wall
Thermal
Temperature
450
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BND_Liner
Sel. for BC
BND_Liner
Name of BC
BND_Liner
Type of BC
Wall
Thermal
Temperature
450
BND_Piston
Sel. for BC
BND_Wall
Name of BC
BND_Wall
Type of BC
Wall
Movement
Mesh Movement
Thermal
Temperature
450
BND_Intake_
Ports
Sel. for BC
BND_Intake_Ports
Name of BC
BND_Intake_Ports
Type of BC
Wall
Thermal
Temperature
330
BND_Exhaust_
Ports
Sel. for BC
BND_Exhaust_Ports
Name of BC
BND_Exhaust_Ports
Type of BC
Wall
Thermal
Temperature
550
BND_Intake_
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Sel. for BC
BND_Intake_Valves
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Valves
Name of BC
BND_Intake_Valves
Type of BC
Wall
Movement
Mesh Movement
Thermal
Temperature
330
BND_Exhaust_
Valves
Sel. for BC
BND_Exhaust_Valves
Name of BC
BND_Exhaust_Valves
Type of BC
Wall
Movement
Mesh Movement
Thermal
Temperature
550
BND_Intake_
Seats
Sel. for BC
BND_Intake_Seats
Name of BC
BND_Intake_Seats
Type of BC
Wall
Movement
Mesh Movement
Thermal
Temperature
330
BND_Exhaust_
Seats
Sel. for BC
BND_Exhaust_Seats
Name of BC
BND_Exhaust_Seats
Type of BC
Wall
Movement
Mesh Movement
Thermal
Temperature
550
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BND_Squish
Sel. for BC
BND_Squish
Name of BC
BND_Squish
Type of BC
Wall
Movement
Mesh Movement
Thermal
Temperature
550
5.11.2.4. Fluid Properties (Air)

In the Fluid properties folder in the parameter tree, select FP[1]: NoName to access the
Fluid properties of input field. Select Air from the pull-down menu.
5.11.2.5. Initial Conditions

Select Initial conditions in the parameter tree to access the following input fields:
Pressure
115830
Pa
Density
1.19
kg/m3
Temperature
957.1
Turb. kin. energy
m2/s2
Turb. length scale
0.001
Initialization mode
Uniform initialization
1-Equation-turbulence model
Deactivated
Reinitialization
Not activated
Smoothing
Activate Smoothing for

Pressure/Temperature from 360 deg CA for
50 Iterations
Type of hydrocarbon fuel
N-Octane
EGR mass fraction
EGR composition
Equivalence ratio
Activate radio button
Insert a new initial condition by selecting Initial conditions in the parameter tree with the
right mouse button and selecting IC: Insert from the submenu.
Select IC[1]: NoName to access the following input fields:
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Sel. for IC
INI_Intake_ports
Name of IC
INI_Intake_ports
Pressure
107369
Pa
Density
1.19
kg/m3
Temperature
325.5
Turb. kin. energy
m2/s2
Turb. length scale
0.001
Initialization mode
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Deactivated
Reinitialization
Deactivated
Smoothing
Deactivated
EGR mass fraction
EGR composition
Equivalence ratio
Sel. for IC
INI_Exhaust_ports
Name of IC
INI_Exhaust_ports
Pressure
127940
Pa
Density
1.19
kg/m3
Temperature
950
Turb. kin. energy
m2/s2
Turb. length scale
0.001
Initialization mode
Deactivated
Reinitialization
Deactivated
Smoothing
Deactivated
EGR mass fraction
EGR composition
Equivalence ratio
Sel. for IC
INI_Exhaust_seats_gap
Name of IC
INI_Exhaust_ seats_gap
Pressure
127940
Pa
Density
1.19
kg/m3
Temperature
950
Turb. kin. energy
m2/s2
Turb. length scale
0.001
Initialization mode
Deactivated
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Reinitialization
Deactivated
Smoothing
Activated (refer to Figure 5-149)
EGR mass fraction
EGR composition
Equivalence ratio
Figure 5-149: Smoothing exhaust valve seat area @864.4CA

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Sel. for IC
INI_Cylinder
Name of IC
INI_Cylinder
Pressure
115830
Pa
Density
1.19
kg/m3
Temperature
957.1
Turb. kin. energy
m2/s2
Turb. length scale
0.001
Initialization mode
Deactivated
Reinitialization
Activate reinitialization for Equivalence

ratio at 617 deg CA to 1.14173. Use
homogeneous initialization.
Smoothing
Deactivated
EGR mass fraction
Equivalence ratio
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5.11.2.6. Solver Control

In the Solver control folder in the parameter tree, select the following in the parameter
tree to access the relevant input fields:
Discretization
Equation
control
Activate
equations
Underrelaxation
factors
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Calculation of
boundary values
Extrapolate
Calculation of
derivatives
Least Sq. Fit
Variable Limits
No
Cell face
adjustment equation
Yes
Cell face
adjustment geometry
No
Realizability
Constraints
No
Decoupled
Constraints
No
Simple
Momentum &
Continuity
Yes
Turbulence
k zeta - f
Energy
Yes, Total enthalpy
Viscous heating
Yes
Pressure work
Yes
Scalar
No
Pressure reference
cell
Pick: In the graphical viewer

select a cell on the inlet face.
Two stage pressure

correction
No
Compressibility
Compressible
Wall Treatment
Hybrid Wall Treatment
Heat Transfer
Wall Model
Standard Wall Function
Momentum
0.6
Pressure
0.4
Turb. kin. energy
0.4
Turb. diss. rate
0.4
Energy
0.8
Mass source
Viscosity
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Differencing
scheme
Species transport
equations
0.8
Momentum
MINIMOD
Relaxed
Continuity
Central
Differencing
Turbulence
Upwind
Energy
Upwind
Scalar
Upwind
Select Linear solver and enter the following values:

Linear solver type
Min iteration
Max iteration
Tolerance
Momentum
GSTB
50
0.1
Continuity
AMG
50
0.01
Turbulence
GSTB
50
0.1
Energy
GSTB
50
0.1
Scalar
GSTB
50
0.1
Select Convergence criteria and enter the following values:

Convergence
criteria
Max. number of iteration
100
Min. number of iteration
Reduction of residuals
Activate
Pressure (activate toggle

switch)
Table
upto crank-angle Pressure
upto 582
upto 862
upto 1080
0.005
0.001
0.005
5.11.2.7. Output Control

Select the following in the parameter tree to access the relevant input fields:
1.
Write 2D result file (<Casename>.fl2)

The 2D result file (<Casename>.fl2) contains the output of mean values of flow
quantities from the simulation for the whole domain or selection based. Besides the
standard output (refer to following step 1), it is also possible to write out results by
predefined formulae (refer to following step 2).
Mean values for the whole domain
Select Write 2D result file in the parameter tree and activate the toggle switches
for Flow quantities, Turbulence quantities and Wall summary.
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Mean values selection based

This section describes how to create an extended output for the Tumble. The
theory behind this formula has not been discussed in this manual, as it is assumed
that the user has the required knowledge.
1. Insert a new field by selecting Write 2D result file in the parameter tree with
the right mouse button and selecting 2D: Insert from the submenu.
2. Then select 2D[1]:NoName and select the INI_Cylinder selection from the pulldown menu.
3. INI_Cylinder is taken as default for the Name of 2D output.
4. Select New quantity by formula, a new button with label Formula_1 appears.
Select this button and the FormulaEditor window opens automatically with
empty fields.
5. Import a predefined formula by selecting Import Example. Automatically you
will be directed to the directory where this predefined formula is stored.
6. Locate the following formula: Relative_angular_speed_at_half_stroke.h and
confirm with OK.
7. Select Edit formula parameters and specify the input.
8. For Name of result quantity enter Tumble:- and select OK to leave the
FormulaEditor window.
2. Write 3D result file (</3D_Results/DOM_x/AN_XYZ.fl3_step_x)
Enter the following values for Output frequency in the Table
upto
crank-angle
each
upto
400
upto
500
10
upto
690
20
upto
705
upto
740
10
upto
1080
30
Select the following parameters:
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Density
Yes
Mach number
Yes
Passive Scalar
No
Pressure
Yes
Temperature
Yes
TKE and Turb. diss.
Yes
Velocity
Yes
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Viscosity
Yes
Vorticity
No
Wall heat transfer

(greyed out)
Yes
Momentum error
Yes
3. Write restart file (<Casename>.rs0, <Casename>.rs1)

Select Write restart file
Output frequency
5 deg
4. Write backup file (<Casename>.bc_0692, etc)

Deactivate Write backup file
Select File | Save and save the project.
5.11.3. Modules
5.11.4. Combustion
Module
Combustion
Parameter Tree
Action
Control
Extended output
On
Ignition models
Spark ignition
Active
On
Active
Number of spark Spar

locations
1
x=0
y = -0.0015
z = 0.00652
Spark timing
697
Flame kernel size
0.003
Ignition duration
0.0003
Coherent Flame
Model
Activate
ECFM-3Z
Activate
Model constants:
Use default values
Time scale:
Local
Combustion
models
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GUI Options
2D Results
Default values
3D Results
Default values
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5.11.5. User defined parameters

Set USER_AST_DEFAULT to value 1
5.11.6. Save Project

Select File | Save and save the project.
5.12. Start Calculation
hardware capabilities and model size for single and parallel run. For details
refer to Chapter 6.8 of the FIRE Workflow Manager Users Guide.
5.12.1. Monitoring the Calculation

5.12.1.1. Monitoring the .flb-file
During the calculation the user can observe the different values and residuals.
This information is stored in the .flb-file, which is written in binary format and can be seen
as described in the following steps.
Open the following window by selecting 2D Log in the project tree with the right mouse
button and then View from the submenu or by selecting 2D Log from the SG Application
Bar. The default window has four empty sections. The following figure shows the residual
output exemplary.
Figure 5-150: Log Monitoring Window

Each section of the monitoring window contains two tabs.
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Select the Data tab to show the values and residuals for each iteration of each selected cell.
The table is updated automatically.
Select the Monitor tab to show the values and residuals for selected cells in a 2D graph.
Display required data in a graph, e.g. Monitor 3, as follows:
1. Select the Monitor 3 tab.
2. Select the relevant quantity in the tree on the left.
5.12.1.2. Monitoring the .fla-file (Linux Users only)

This is a useful procedure to monitor the .fla-file as possible error messages may be written
to it.
1. To observe the .fla-file during calculation, open a new shell.
2. Go to the directory where the project is stored.
3. Select the desired Case directory (e.g. <path_of_project>/Calculation/Case/)
4. Type the command: tail f *.fla
This command displays the last part of a file. The f command reads and copies further
bytes from the input file when they become available.
5.13. Post-processing
The IMPRESS post-processor displays the results which are stored in the .fl3-file. Several
flow variables can be displayed in different cut planes at selected iterations side by side.
5.13.1. Load Results

Load the results for cTEC_Engine as follows:
1.
Select 3D Results in the project tree with the right mouse button.
2.
Select Load complete angle(s) from the context menu and choose (exemplary)
470CA. All results are loaded.
5.13.1.1. Create surface cut and create a movie

Display desired data in Cut planes as follows:
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1.
Open the IMPRESS post-processor by selecting it from Application Bars in the View
menu or select the IM icon in the upper right corner.
2.
In the project tree, select Impress-Cuts with the right mouse button, select Create ->
Surface -> 961_ESE_Engine(moving_1) from the submenu to access the cuts.
Alternatively click on the mesh to activate the Cuts in the IMPRESS Application Bar.
Ensure that the mesh is selected.
3.
The Properties window opens automatically. If the mesh is on default position, move
it aside to show the cut.
4.
Select the Data settings tab.
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5.
Select Flow:Temperatur[K] from the Display attribute pull-down menu.
6.
Select Scalar values at cell vertices. Refer to following figure.
Figure 5-151: Plane cut Velocity at 470 CA
7. Select Tools from the IM Application Bar and select
to open the Movie Maker.
8. Click on beside Viewer to open the tree. Then double click Data step and the new
action will be added to description board below.
9. Enter 365 for Start datastep and 1080 for End datastep
10. Enter 40 for End frame. This specifies how many frames the video should contain.
11. Select the Start button to view the animation on screen.
12. To save the movie on disk select Save as video from the Result pull-down menu.
13. Then select the Start button again to define Filename, Path, Videotype (Avi, Mpeg1
for Video CD quality or Mpeg2 for DVD quality) and Compression (not required for
Mpeg2) for the movie.
14. Confirm by clicking OK. There may be a delay while the animation file is being created,
depending on the movie length and CPU speed.
15. The Movie Maker window will reappear when the animation file is completed.
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Note: Some experimentation may be necessary to achieve the best movie

capture. If required change the viewer width and height by selecting Extras |
Options and then enter appropriate values for Viewer width and Viewer
height.
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16. Click File | Leave director to close the window.
5.14. Geometry variation

Once a project has been set up and completed successfully it can be used as template for
geometry variations. Typical geometry variation variations are port design but also
chamber (squish) and piston bowl modifications.
To ensure a save transfer of project settings to a new geometry use ESE Engine
Component modeler.
5.14.1. Intake port variation

When only the port design is changed (above rotation symmetric section of valve seat area)
a new static mesh (described in chapter 5.7.1) and the assembly step (refer to chapter 5.8)
needs to be done. Use ESE Engine Component modeler to create the new surface input.
Figure 5-152: Intake port (injector) design variation

The Component Modeler can be started from AST Launcher.
Figure 5-153: Start ESE Engine Component Modeler
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fire_ese_engine_component_modeler
fire_ese_engine_component_modeler.exe
5.14.1.1. Port cutter

The operation mode is Port cutter.
5.14.1.2. Load Chamber Modeler project

Load the ESE Engine Chamber Modeler project. Click on ESE Engine project file in the
menu bar and expand the project tree by clicking on
file from the 01_Chamber_Modeler folder.
. Open the ESE Engine project

Click
5.14.1.3. Load Surface file

Load the new surface file. Click on Surface file in the menu bar and expand the project
tree by clicking on
model.
. Click on the 00_Input folder in the project tree and select the edge
Locate the file Surface_IV0p15mm_EV_closed_Piston_TDC_modInjection.flm in:

<InstallationPath>/FIRE/v2011.1/exam/961_ESE_Engine_Geometry_variation/00_Input.

Load the new edge file. Click on Edge file in the menu bar and expand the project tree by
clicking on
. Click on the 00_Input folder in the project tree and select the edge model.
Locate the file Edges_IV0p15mm_EV_closed_Piston_TDC_modInjection.flm in:

5.14.1.5. Crank angle (virtual position setup)

The global parameter which needs to be defined is whether the loaded surface represents a
real engine position or if this is a virtual surface. The loaded input surface is identical to
the original one which has closed exhaust valves, the intake valves are open 0.15mm and
the piston is at TDC.
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Since only the port surfaces are of interest the piston position is not relevant for this task.
Set the Movement type to Axis offset. Set value for the intake valves to 0.15mm and for
the exhaust valves to 0.0mm
5.14.1.6. Run port export and output

To specify the output file path click on Output in the menu bar and expand the project tree
by clicking on
. Click on Create Folder to create a new sub-folder.
Define a name for the ESE Engine Component Modeler folder.

Click on OK to confirm the input.
Click Run port export to start the port cutting process.
Figure 5-154: ESE Engine Component Modeler, port cutter
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5.14.2. Piston bowl and squish design variation

If geometry design changes in the cylinder area (chamber, piston) as well as in the valve
seat region the feature Surface exchange in ESE Engine Component modeler shall be
used.
To demonstrate the method how to transfer project settings to a design modification of the
baseline geometry two modifications have been made on the original surface. As shown in
Figure 5-155 the flat piston (left side, original surface) is replaced by a synclinal bowl
contour (right side, design variation) and on the intake side the squish area has been
reduced for the design variation case.
Figure 5-155: Piston bowl and squish area modification

Both geometries share same point of origin and also use the same valve timings for inlet
and exhaust valves.
Use ESE Engine Component modeler to transfer the setup to the new surface input. Start
the Component Modeler from AST Launcher or with the shell command.
5.14.2.1. Surface exchange

Select the operation mode Surface exchange.
5.14.2.2. Load Chamber Modeler project

Load the reference ESE Engine Chamber Modeler project. Click on ESE Engine project
file in the menu bar and expand the project tree by clicking on
project file from the 01_Chamber_Modeler folder.
. Open the ESE Engine

Click

Load the new surface file. Click on Surface file in the menu bar and expand the project
tree by clicking on
model.
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. Click on the 00_Input folder in the project tree and select the edge
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Locate the file Surface_IV0p15mm_EV_closed_Piston-2_TDC_modSquish.flm in:

5.14.2.4. Load Edge file

Load the new edge file. Click on Edge file in the menu bar and expand the project tree by
clicking on
. Click on the 00_Input folder in the project tree and select the edge model.
Locate the file Edges_IV0p15mm_EV_closed_Piston-2_TDC_modSquish.flm in:

5.14.2.5. Define output folder and run surface exchange

To specify the output file path click on Output in the menu bar and expand the project tree
by clicking on
. Click on Create Folder to create a new sub-folder.
Define a name for the ESE Engine Component Modeler folder.

<UserPath>/961_ESE_Engine_Geometry_variation/01_Chamber_Modeler
Click on OK to confirm the input.
5.14.2.6. Reference system and initial valve meshes

Recalculating the cylinder and valve reference system is required if
-
the new model has been shifted (i.e. moved and/or rotated position)
engine characteristic has changed (i.e. bore, valve angle, valve alignment)
Note: Considerable changes in the model input might affect the capability of
mapping settings from the reference project to the new input data.
Since the surface is at the same position and nor bore, valve angle or the valve alignment has
changed Recalculate reference system for valves and Recalculate reference system for
cylinders is off.
To run the valve as well as the 2D template steps right after the data has been transferred to
the new surface tick off Perform initial valve mesh calculations on new project.
5.14.2.7. Run surface exchange

Click Run surface exchange to start the process.
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Figure 5-156: ESE Engine Component Modeler, surface exchange

ESE Engine Component Modeler transfers all settings to the new project and starts ESE
Engine Chamber Modeler and automatically performs the valve as well as the 2D template
meshes.
Figure 5-157: 2D template for baseline and modified chamber design

Datasets need some re-adjustment after the mapping process has finished. As shown in
Figure 5-158 some datasets the valve mesh gain attention. Open the red marked datasets
for check and repair.
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Figure 5-158: Data transfer and initial valve mesh finished

On three datasets the most outer valve seat block corner (refer to Figure 5-159) needs to be
corrected to get a valid setup.
Figure 5-159: Intake valve mesh on new surface

Finally all remaining datasets can be generated automatically using Execute all. This should
be done only if no changes in the 3D template setup are required.
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Note: 3D template setup needs to be updated if the new surface features

significant changes in the piston and/or chamber design.
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Figure 5-160: Execute all

One dataset after another is executed automatically. The result of the finished project is
shown in Figure 5-161. In a final step the new chamber model can be assembled with the
existing intake and exhaust ports as described in chapter 5.8.
Figure 5-161: Chamber Modeler project done for surface variant
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Edition 05/2012

Engine Simulation Environment (ESE) Tutorial

AVL List Gmbh 2009. All right reserved

AVL LIST GmbH

FIRE v2008 ESE Tutorial

Copyright 2012, AVL

2. ESE Diesel (922) _________________________________________________2-1

3. ESE Diesel 02: ESE_D / BOOST coupling (927) ___________________3-1

3.6.2. ROHR Treatment in BOOST______________________________________________ 3-18

4. ESE Aftertreatment (933) ________________________________________4-1

5. ESE Engine (961) ________________________________________________5-1

5.6.10. Create dataset from 254 CA to 330 CA ___________________________________ 5-79

Figure 3-14: Shell Output When Project is Saved ............................................................................................... 3-12

Figure 5-7: Selections on the input edges ............................................................................................................... 5-8

Figure 5-105: Dataset range at exhaust valve closing .......................................................................................... 5-72

1.2. User Qualifications

Must be qualified in basic Linux and/or Windows.

Must be qualified in basic CFD (Computational Fluid Dynamics).

This document is a basic qualification for operating the FIRE Workflow

Caution: Cautions describe conditions, practices or procedures which

Note: Notes provide important supplementary information.

For emphasis, to introduce a new term or for manual

To indicate a command, a program or a file name,

A MenuOpt font is used for the names of menu options,

FIRE Workflow Manager Users Guide

Combustion / Emission Module

We Want to Hear from You

2. ESE DIESEL (922)

Figure 2-1: Diesel Cake - Overview

Figure 2-2: Diesel Cake Detail radius

Figure 2-3: General Mesh Properties

2.2. Start ESE Session

Open a new shell window.

Type the following command to start ESE Diesel standalone version:

2.2.2. Standalone Version for Windows

2.3.1. General Data

Figure 2-4: General Engine Parameters

Figure 2-5: Piston Movement Specification

Define the piston bowl shape (Piston)

Define the injector shape (Injector)

Modify the block-structure of a template (Block structure)

Define details related to selections (Selections)

Please perform the following steps to create the geometry:

Figure 2-6: Piston Template Diesel Bowl 2

Figure 2-7: Piston Geometry Parameters

Figure 2-8: Invariant Piston Parameters

Figure 2-9: Injector Geometry Parameters

Figure 2-10: Block Structure Parameters

Figure 2-11: Piston Bowl - Final Shape

Figure 2-12: Injector Location - Detail

Figure 2-13: Sketcher Window - Selections Specification

Figure 2-14: Meshing Parameters

Select Generate 2D meshes to create a set of 2D computational meshes covering the

Figure 2-15: Moving Set Exemplary for range of 0 CA to 20 CA

Figure 2-16: 3D Meshing Parameters

2.3.4. Simulation Parameters

2.3.4.1. Overview of Typical Boundary Conditions

Figure 2-17: Boundary Conditions Overview

Figure 2-18: Boundary Conditions Details

Figure 2-19: Moving Wall Adiabatic Boundary Conditions

Figure 2-20: Selections for Cyclic Boundary Conditions

2.3.4.2. Define Data for Calculation

2.3.4.2.1. Run Mode

2.3.4.2.2. Module Activation