Validation Verification Internal Combustion Ansys

Validation and Verification of ANSYS Internal Combustion Engine Software
Martin Kuntz, ANSYS, Inc.
Contents
Definitions Internal Combustion Engines Demonstration example Validation & verification Spray box Combustion Port flow applications IC engine applications
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 2
Contents
Definitions
Verification Verify, that model is implemented correctly Characteristics
Simplified geometry Focused on single physical model Compare to analytical or other CFD
Validation Demonstrate simulation accuracy Characteristics

Realistic geometry A combination of physical models Compare to experimental data
Demonstration Illustrate application of software to generic case Characteristics

Realistic geometry A combination of physical models No comparison to data
Wednesday, October 10, 2012
2012 Automotive Simulation World Congress
Contents
IC Engine Simulations Types

Component simulations Intake port, intake manifold, water jackets, fuel injectors Spray bomb IC engine simulations Cold flow
Charge motion
Combustion
Thermal management Emissions
ICE Simulation Workflow

Internal combustion engine simulation components Preprocessing
Geometry decomposition Initial meshing Simulation parameter definition
Moving deforming meshes

Smoothing, remeshing, layering
Particle tracking
Injection, tracking, evaporation, wall-interaction
Combustion
Ignition, flame front propagation
Post-processing
Automatic processing of monitor and solution data
Contents
Demonstration : Direct Injection Gasoline Engine

Complete cycle setup
Initial conditions and boundary conditions provided by 1D simulation Material Iso-octane Spray injection
6-hole injector Double injection Transient mass flow Prescribed diameter distribution
Liquid evaporation model Spark ignition G equation combustion
Testcase provided by BMW

Courtesy: BMW

Initialization Burned conditions at EVO Boundary condition Specified temperature Mesh size: cell count 800.000 (TDC) to 1.600.000 (BDC)
10

Simulations
Cold flow run Charge motion
Plus spray injection Plus particle tracking
Combustion
Plus ignition Plus flame front propagation
11

Cold flow simulation Results for CFX and Fluent Cylinder averaged values of pressure and temperature
12

Cold flow simulation Results for CFX and Fluent Swirl ratio, tumble ratio
13

Velocity vector plots
CA 330 CA 440
CA 555
CA 715
14

First injection
15

Evaporation
16

Second injection
17

Total particle mass Influence of wall film model
Combustion simulation
19

Burned flow simulation Cylinder averaged values
Pressure Temperature Mixture fraction
20 Wednesday, October 10, 2012
Contents
Validation: Particle Tracking

Particle injection
Primary / secondary breakup Injection type: cone / hollow cone
Testcases
Bosch spray box (cold spray) Hiroyasu spray box (cold spray) Koss spray (hot spray)
Tracking
Particle-wall interaction Wall film modeling
Evaporation
Validation: Bosch Spray Box

Two cases based on experimental data from ROBERT BOSCH GmbH Details of experimental setup
Setup # 1 Gas param eters Setup # 2
Gas type Temperature [K] Pressure [MPa]

Fuel Properties
N2 300
0.00275 m
0.56
0.11
Heptane 614.2 0.0201
Fuel type Density [kg/m3] Surface tension [kg/s2]
0.03 m
sampling point (0, 0.00275, 0.03)
Spray parameters Initial temperature [K] Nozzle diameter [mm] Injection pressure [MPa] Injection velocity [m/s] Particle mass flow rate [g/s] Injection rate, single pulse [ms] Estimated initial spray angle [deg] Injection Weber number 5.2 85 300 0.151 10 138 1.5 1.5 12 450
Available data
Spray penetration over time Sampling point (0, 0.00275, 0.03) - Droplet diameter distribution - Droplet velocity distribution
Kumzerova, E. and Esch, T., Extension and Validation of the CAB Droplet Breakup Model to a Wide Weber Number Range, Proc. of the 22nd Europ. Conf. on Liquid Atomization and Spray Systems, Paper ILASS08-A132, Como Lake, 2008.

Mesh dependence study
Grid
Number of cells 364

735 1450
Size of the cell near the nozzle [m 2] (radial x axial length) 12.8e-4 x 12.8e-4
6.4e-4 x 6.4e-4 3.2e-4 x 3.2e-4
Coarsest
Coarse Medium
Fine Finest
2880 5824
1.6e-4 x 1.6e-4 8e-5 x 8e-5
Coarsest
Coarse
Medium
Fine
Finest
24

Mass penetration Mesh dependence study Fluent simulation Setup #2
25

Local spray results at sampling point
Droplet diameter distribution Local velocity distributions KH-RT breakup model Setup #1

Local spray results at sampling point
Droplet diameter distribution Local velocity distributions KH-RT breakup model Setup #2

Mass penetration Comparison KH-RT and SSD break-up model Fluent simulation Setup #2
28

Mass penetration Comparison of break-up models CFX simulation Setup # 2 E xperiment
0.1
Penetration Depth [m ]
0.08 0.06 0.04 0.02

00
No breakup R eitz &D iwakar S chmehl T AB E T AB C AB
0.0005
0.001
Time [s]
Medium grid (4000 nodes) dt = 2e-6 s 0.0015 0.002
Validation: Hiroyasu Spray Box

Case 1
Gas parameters Gas type Temperature [K] Pressure [MPa] Fuel Properties Fuel type
Density [kg/m3 ]
Case 2
Case 3
N2 300 1.1 C12H26 840 0.0205 300 3.0 300 5.0
Surface tension [kg/s2]

Spray parameters
Initial Temperature [K]

Injection Velocity [m/s]
300 102 6.05 0.3 2.5
300 90 5.36 0.3 4
300 86 5.13 0.3 4
Particle Mass Flow Rate [g/s] Nozzle diameter [mm]

Injection rate, single pulse, ms
Validation: Hiroyasu Spray Box

Mass penetration Case 1, 2 and 3 Fluent simulation
Validation: Koss Spray Box

Gas Temperature [K] Gas Pressure [MPa] Gas Type Particle Mass Flow Rate [g/s]
Droplets type
800 5 N2 4.62
nHeptane (C7H16)
Evaporating spray
Liquid penetration at 90% spray mass fraction
Density [kg/m3] Surface tenstion [N/m2] Nozzle diameter [mm] Injection rate [ms] Droplet diameter [mm] Injection Velocity [m/s] Initial spray angle [deg]
684 0.02 0.2 1.3 0.2 215 10.1

Liquid penetration Length
Measurements: H. Koss, D. Bruuggemann, A. Wiartalla, H. Backer, and A. Breuer, Results from Fuel/Air Ratio Measurements in an N-Heptane Injection Spray, IDEA periodic report, RWTH Aachen, 1992.

Breakup model comparison TAB ETAB CAB Reitz CFX run

Comparison Fluent KH-RT model CFX TAB model
Contents
Validation: Hamamoto Testcase

Premixed combustion in a closed vessel with fixed wall Propane/air mixture: Equivalence ratio =1.0 Measured data Optical access Pressure transducer Described in
Hamamoto et al. (1988) Ewald (2005)
36

Average cylinder pressure Mesh sensitivity study Fluent, 2d quad meshes Comparison CFX vs. Fluent

Average cylinder pressure Comparison of mesh size and types 3D hexahedral and tetrahedral meshes
Combustion Validation: Pancake Engine

Premixed combustion Flat head, flat piston, SI ICE Fuel: C3H8 References: Alkidas (1980) Han and Reitz (1997) Simulated interval [-30;30 CA] ATDC Piston motion
Displacement [m3] Bore x Stroke [mm] Compression ratio
Connecting rod length [mm]
0.82 x 10-3 105.0 x 95.25 8.56

158
TDC clearance [mm] Equivalence ratio Engine speed [rpm] Spark timing [deg. ATDC]
Volumetric efficiency
12.6 0.87 1500 -27

40
39
Combustion Validation: Pancake Engine

Average cylinder pressure G equation combustion Comparison CFX Fluent
40
Contents
ICE Validation
IC engine applications Public engine cases Collaborations with customers Benchmark for customers Of interest
Valuable experimental data No confidentiality No restrictions for publication
42
ICE Validation: Engine Applications

Port flow simulation Thobois generic engine Cold flow simulation Bosch: direction injection diesel engine with PIV data Partially premixed combustion Wisconsin: direct-injection spark-ignition engine Premixed combustion Ducati: premixed engine setup Diesel combustion Engine cooling simulation
43
ICE Validation: Port Flow

Steady intake flow conditions Testcase defined in Large Eddy Simulations in IC Engine Geometries
Thobois, Rymer, Souleres, Poinsot SAE Paper, 2004-01-1854
Port length Inner port diameter Outer port diameter Valve opening Cylinder length Cylinder diameter
132 mm 16 mm 34 mm 10 mm 300 mm 120 mm

44

Comparison
RANS SST model LES SAS model
CFX results
Isosurface S 2 2 106 Color eddy viscosity

45

Plane @ 20 mm Mean Axial Velocity
Axial Velocity Fluctuation

Plane @ 70 mm Mean Axial Velocity
Axial Velocity Fluctuation
Validation: Bosch Engine

Experiment Investigation of Diesel engine in-cylinder flow with Particle Image Velocimetry (PIV) and High-Speed PIV Generation of a comprehensive and high-quality database for Large Eddy Simulation Simulation RANS & Scale resolving turbulence models, e.g. LES, DES CFX simulation
Publications
A Strategy for Evaluation of LES Applied to Diesel Engine InCylinder Flow Joint Effort of Simulation and Experimental PIV Flow Analysis Les Rencontres Scientifiques de l'IFP LES for Internal Combustion Engine Flows - 18-19 November 2010 Analysis of In-Cylinder Air Motion in a Fully Optically Accessible 2V-Diesel Engine by Means of Conventional and Time Resolved PIV 9TH INTERNATIONAL SYMPOSIUM ON PARTICLE IMAGE VELOCIMETRY PIV11, Kobe, Japan, July 21-23, 2011

RANS simulation
Flow characteristics swirl
Rs
5 4
Swirl Ratio [-]
z 2 N
r V v dV 2 r dV
V
3 2 1 0 -1 360
Average swirl on planes Simulation Experiment (plane data) Experiment SwirlICE ration in cylinder CFX Swirl
450
540 [cad]
630
720
49

Scale Resolving Models LES Large Eddy Simulation DES Detached Eddy Simulation SAS Scale Adaptive Simulation Grid size: 1.2 6.8 106 nodes
50

Comparison of velocity profiles Sample line: -10mm below dome Exp: 2D-2C absolute velocity Sim: 3D-2C absolute velocity
Sample Line
Validation: Wisconsin Engine

Research project conducted at University of Wisconsin sponsored by ANSYS Inc. Characterization of Direct-Injection Spark-Ignition Operation and Investigation of Particulate Matter Formation" Research work of single-cylinder direct-injection spark-ignition engine November 2011 November 2013
52

Riccardo Hydra Base Modern DISI engine architecture
Engine Specifications
Engine Type Chamber Geometry Fueling type Displacement 4-Stroke, 4-Valve, SI Pentroof Spray-guided directinjection 692.9 cm3 12:1
11 MPa
53
Single-cylinder direction-injection spark-ignition engine used for measurements

Compression Ratio
Injection Pressure

Phase 1 single cylinder metal engine Motored operation Fired homogeneous (fully vaporized) spark-ignition operation with premixed air/fuel mixtures Direct-injection spark-ignition operation Phase 2 detailed investigations Detailed spray characterization measurements in a spray vessel Laser-based in-cylinder measurements to characterize the velocity field or fuel distribution Detailed measurements of particulate matter number count
54

Motored Engine Measurements Repeatability Influence of coolant temperature
2
Cylinder Pressure [bar]
10
8 6 4 2
8 6
6 7 8 9
6 7 8 9
0.1
Volume [L]
In-cylinder pressure for 2000 rpm 80 kpa, 80 oC intake, 80 oC coolant

55
Validation: Ducati Engine

4-stroke S.I. P.F.I. race engine Premixed combustion Validation / verification Pressure trace Collaboration University of Bologna, Ducati Motor Holding & ANSYS
Publication Flexible Meshing Process and Multi-cycle Methodology for Simulating Reacting Flows in High Performance SI Engines with ANSYS CFX
International Multidimensional Engine Modeling Users Group Meeting 2010 (IMEM 2010), Detroit, April 12th, 2010
56

Simulation with CFX Efficient multi-cycle methodology
Single-cycle initialization / multi-cycle initialization
Influence of mesh resolution & types
57

Simulation with Fluent Variation of combustion models / turbulent flame speed models and settings
cylinder pressure [bar] Average EXP. MEAN IN-CYLINDER PRESSURE [bar]
140
120 100
80
10000 rpm Cyl_Horiz 10000 rpm Cyl_Vert ECFM - cycle 1 C-eqn - cycle 1
G-eqn - cycle 1
G-eqn zcd - cycle 1
G-eqn p - cycle 1
60 40
20
G-eqn pc - cycle 1
0 -360
-20
-270
-180
-90
90
180
270
360
CRANK ANGLE [deg. ATDC] Crank Angle [deg]
58
Validation: Engine Cooling Simulation

Perform Engine Cooling Simulation Requires simultaneous simulation
IC engine simulation Cylinder head coolant channel simulation
Thermal inertia of two models is orders of magnitude different two separate simulations
59

Steady state conjugate heat transfer of cylinder head Transient combustion simulation in diesel engine in-cylinder
Time-averaged Heat Flux profile on cylinder head
Iterative Process
Temperature profile on the firedeck

Import: temperature data
Iteration process
Export: time-averaged heat flux from IVC to EVO

Heat Flux n-heptane 1 step mechanism Effect of mesh resolution
y+~ 200
y+~ 30
y+~ 20
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress
y+~ 1
62

Heat Flux n-heptane 1 step mechanism Effect of combustion and turbulence model
K-epsilon
K-epsilon
Laminar Finite Rate
Finite Rate - Eddy
SST K-w
SST K-w
Laminar Finite Rate

Finite Rate - Eddy

63

Temperature data at locations of thermocouples Heat Flux n-heptane 1 step mechanism + SST k model (Laminar Finite Rate)
64
Summary
Validation and verification examples related to internal combustion engines Basic spray and combustion cases Port flow applications Cold flow IC engine applications Combustion IC engine applications Good agreement of results for most cases in different application areas Ongoing work in the ICE validation project at ANSYS Continuation of work with existing engines Collection of new validation cases Reference cases for current ICE software and future software developments
65
Any Questions ?
66

Validation Verification Internal Combustion Ansys

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Validation Verification Internal Combustion Ansys

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Validation and Verification of ANSYS Internal Combustion Engine Software

Martin Kuntz, ANSYS, Inc.

Validation Demonstrate simulation accuracy Characteristics

Demonstration Illustrate application of software to generic case Characteristics

2012 Automotive Simulation World Congress

IC Engine Simulations Types

2012 Automotive Simulation World Congress

ICE Simulation Workflow

Moving deforming meshes

2012 Automotive Simulation World Congress

Demonstration : Direct Injection Gasoline Engine

Liquid evaporation model Spark ignition G equation combustion

Testcase provided by BMW

2012 Automotive Simulation World Congress

Demonstration : Direct Injection Gasoline Engine

Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Demonstration : Direct Injection Gasoline Engine

Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Demonstration : Direct Injection Gasoline Engine

Wednesday, October 10, 2012

Demonstration : Direct Injection Gasoline Engine

Wednesday, October 10, 2012

Demonstration : Direct Injection Gasoline Engine

Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Demonstration : Direct Injection Gasoline Engine

Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Demonstration : Direct Injection Gasoline Engine

Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Demonstration : Direct Injection Gasoline Engine

Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Demonstration : Direct Injection Gasoline Engine

Demonstration : Direct Injection Gasoline Engine

2012 Automotive Simulation World Congress

Demonstration : Direct Injection Gasoline Engine

20 Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Validation: Particle Tracking

Validation: Bosch Spray Box

Gas type Temperature [K] Pressure [MPa]

Fuel type Density [kg/m3] Surface tension [kg/s2]

sampling point (0, 0.00275, 0.03)

Validation: Bosch Spray Box

Number of cells 364

1.6e-4 x 1.6e-4 8e-5 x 8e-5

Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Validation: Bosch Spray Box

Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Validation: Bosch Spray Box

Validation: Bosch Spray Box

Validation: Bosch Spray Box

Wednesday, October 10, 2012

2012 Automotive Simulation World Congress

Validation: Bosch Spray Box

0.08 0.06 0.04 0.02

No breakup R eitz &D iwakar S chmehl T AB E T AB C AB

Medium grid (4000 nodes) dt = 2e-6 s 0.0015 0.002