2011 ANSYS, Inc.

December 19, 2013 1

In-Cylinder Engine Modeling
using ANSYS CFD
December 19
th
, 2013
2011 ANSYS, Inc. December 19, 2013 2
Outline
ICE System in Workbench
Spray and Combustion Models
Case-Studies and Best Practices
2011 ANSYS, Inc. December 19, 2013 3
Ignition Modeling
Combustion Modeling Optimization
Pollutant Modeling
Workflow: Meshing and
Dynamic Mesh Modeling
Near-wall Heat Transfer
Modeling
Flow Modeling
CFD Modeling of IC Engines
Spray Modeling
2011 ANSYS, Inc. December 19, 2013 4
WB ICE System
IC Engine Simulation Tool
Geometry
Preparation
Meshing
Solver Setup
Simulation
Post-
processing
Geometry Motion
Geometry Decomposition
Meshing templates
Mesh controls
Application specific setup
FLUENT solver
HPC simulation
ICE specific post-processing
Report generation
2011 ANSYS, Inc. December 19, 2013 5
Geometry Preparation
Portflow Simulation IC Engine Simulation Sector Simulation
Geometry
preparation
2011 ANSYS, Inc. December 19, 2013 6
Meshing
Predefined meshing templates
Application specific mesh topology, mesh controls
6 2013 Automotive Simulation
World Congress
Portflow Simulation IC Engine Simulation Sector Simulation
2011 ANSYS, Inc. December 19, 2013 7
Solver Setup
Customized panels
to setup complete IC
engine case
Default parameter settings
for different applications
based on best practise
7
2013 Automotive Simulation
World Congress
Boundary Conditions
Physics Setup
Engine Data
Monitor Definitions
Solution Initialization
Postprocessing
Chemistry
Combustion
Injection
Ignition
2011 ANSYS, Inc. December 19, 2013 8
Post-processing
Automatic report generation Manual post-processing
8
2011 ANSYS, Inc. December 19, 2013 9
Demo
2011 ANSYS, Inc. December 19, 2013 10
An ANSYS Solution for every Simulation
Challenge
High Quality Fuel/Air Mixing
Liquid Fuel Injection
Complex Chemistry
Emission Predictions
Heat Transfer Computation
Configuration Optimization
Advanced Turbulence Models (RANS, SAS, LES)
DPM tracking, Advanced Break-Up Models
Complete Array of Turbulent Chemistry Models
Post-Processing and Coupled Pollutant Models
Advanced Wall Functions and Turbulence Models
Parametric Simulation, Design Exploration
2011 ANSYS, Inc. December 19, 2013 11
Spray Models
FLUENT 14 FLUENT 14.5
Improved wall-film heat transfer
0.00E+00
5.00E-04
1.00E-03
1.50E-03
2.00E-03
2.50E-03
0 1 2 3 4 5
D
p

(
m
)
time (s)
Diffusion-controlled
Convection Diffusion-controlled
Experimental Data symbols
Improved droplet evaporation laws
Single droplet experiment of Wong-Lin

lin const DPM

S S S + =
,
Source term linearization
Volume fraction
standard average
Volume fraction
node based average
Node-based source averaging
KH-RT breakup model
2011 ANSYS, Inc. December 19, 2013 12
Multi-Component Droplet Evaporation
Assume that the evaporation rate of component i is proportional to the
components vapour pressure
Multi-component droplet evaporation model comparison with optical levitation
experiments of J. Wills (PhD thesis, Univ. of Stuttgart, 2005) : Re
d
= 0
total
i vap
i
i
i
p
p
dt dm
dt dm
,
/
/
=

Diameter variation as f(t) for binary mixture of

hydrocarbons
Diameter variation for ternary mixture
2011 ANSYS, Inc. December 19, 2013 13
Spray Modeling
Only - Y
- Y + DPM
Only DPM
Solve for -Y
for Liquid Phase and RANS
equations
Removal from Eulerian
And Injection of DPM
Prepare Inputs for
Lagrangian Phase
Identify the Droplets
in Eulerian Phase
2
~
) ( + +

(
(

|
|

\
|

s
i
i
s
i
i
V a A
x
x
D
x
u
t
i
i
i
i
x
Y u
x dt
Y
Y u

~
' '
~ ~
~

ELSA
Vaporisation Vaporisation
Vaporisation and
secondary breakup
Vaporisation and
secondary breakup
Combustion Combustion
ELSA
Y
-Y
Approaches
Full VOF
Prohibitively CPU expensive
Full DPM
Require inputs like spray angle
ELSA -Y + DPM
UDF Based
Modest cpu requirement
Suitable for IC applications with low liquid to gas density ratio
2011 ANSYS, Inc. December 19, 2013 14
Combustion Models (CI Engines)
Diesel Unsteady Flamelet
model
Solves for 1D Flamelet equation
simultaneously with other transport
equation.
Flamlets generation using CHEMKIN files
The multiple flamelets allow to model:
Split injections
Lifted spray flames
EGR modeling with mixture fraction
Laminar Finite Rate model
Solves individual species transport
equations.
Reactions can be defined using CHEMKIN file
Calculation speed can be increased using
Chemistry Agglomeration features.
2011 ANSYS, Inc. December 19, 2013 15
Partially premixed combustion
model
Combine non-premixed (f) and premixed (c)
models
Progress variable formulation
C-equation model
G-equation model
Chemistry Tabulation
Equilibrium Chemistry
Flame Speed Models
Zimont Flame Speed
Peters Flame Speed
Compressibility Effects
Laminar Finite Rate model
Solves individual species transport
equations.
Reactions can be defined using CHEMKIN
file
Calculation speed can be increased using
Chemistry Agglomeration features.
Combustion Models (SI Engines)
2011 ANSYS, Inc. December 19, 2013 16
Spherical flame assumed
Solve an ODE for the spark flame radius
Four spark flame speed models:
Turbulent Curvature, Turbulent Length, Herweg-Maly,
Laminar
Flame propagates to a transition diameter
Turbulent length scale
Reaction progress in spherical transition volume ramped
up gradually in time
Inputs:
Spark location and initial radius
Since gas behind flame front is equilibrated, no
energy input is required for ignition
Spark Model
2011 ANSYS, Inc. December 19, 2013 17
Efficient Chemistry Acceleration
IN-SITU ADAPTIVE TABULATION
Store Reaction Mappings in an ISAT table
Retrieve Reaction rates when needed
Up to 100 Speed-Up Factor
CHEMISTRY AGGLOMERATION
Agglomerate cells of similar Composition
Call ISAT on Agglomerated Cells
Map Reaction Step back to Original Cells
DIMENSION REDUCTION
User selects the transported Species
Calculate the remaining unrepresented species
using constrained chemical equilibrium
DYNAMIC MECHANISM REDUCTION
Dynamically finds out the optimized reaction
mechanism
Each control volume can have its unique
reaction mechanism
Uses DRG algorithm to reduce the mechanism
2011 ANSYS, Inc. December 19, 2013 18
NO
x
Model
Volatiles, gaseous and
liquid fuel nitrogen
HCN and/or NH
3
N
2
NO
Char nitrogen
NO
x
emission
NO
O
2
Hydrocarbon
radicals, CH
i
NO(reburn)
N
2
(prompt)
N2O
Combustion air O
2
and N
2
2011 ANSYS, Inc. December 19, 2013 19
Soot Modeling
Moos-Brokes model
Solve transport equations for the
soot mass fraction and (normalized)
number density
Moss-Brookes-Hall extension for
higher hydrocarbon (the original
model has been developed for CH4)
2011 ANSYS, Inc. December 19, 2013 20
Homogeneous Combustion in a SI Engine
Engine Specifications
Engine Type 4-Stroke, 4-Valve, SI
Chamber Geometry Pentroof
Fueling type Spray-guided direct-
injection
Displacement 696 cm
3
Compression Ratio 12:1
Injection Pressure 11 MPa (typical)
Measurement data
High-speed in-cylinder
measurements
Pressure, temperature
Cylinder head &liner temperature
Injector characterization
Spray penetration
Diameter and velocity distribution
Measurements
Motored operation
Fired homogeneous (fully
vaporized) spark-ignition operation
with premixed air/fuel mixtures
Direct-injection spark-ignition
operation
Injector characterization
2011 ANSYS, Inc. December 19, 2013 21
INTAKE: P(t), T=Const.
Mean f=0.06052 (phi =0.97)
EXHAUST: P, T=Const.
CHAMBER: Inert =1,
f=0.06052
Wisconsin Homogeneous Combustion: SI
Engine
2011 ANSYS, Inc. December 19, 2013 22
Wisconsin Homogeneous Combustion: SI
Engine
0
10
20
30
40
50
60
70
80
90
100
0
5
10
15
20
25
320 370 420 470 520 570 620 670 720 770
A
H
R
R
,

J
/
C
A
P
r
e
s
s
u
r
e
,

B
a
r
PM_2.5_0.97 Experimental AHRR AHRR-Exp
IVO EVC IVC SPARK
Spark Timing: 2.5 bTDC
RPM: 2000
Intake Air: 80 kpa
Equivalence Ratio: 0.97
CFD Fuel: Iso-octane
CFD Model: G-equation
2011 ANSYS, Inc. December 19, 2013 23
DI Diesel Engine fuelled with Biodiesel
[1]
Hemispherical Shape Piston Bowl
Modified Re-entrant piston Bowls
Central PIP height Varied
All other parameters like compression ratio, bowl volume, fuel injection properties
kept same.
Bowl Shape Optimization for a Bio-Diesel
Engine
[1] Brakora, Jessica L., "A Comprehensive Combustion Model for Biodiesel-Fueled Engine Simulations", PhD Dissertation, University of Wisconsin-
Madison, 2012.
Computational Fluid Dynamic Modeling of In-Cylinder Air Flow, Biodiesel Combustion in a Direct Injection Diesel
Engine, Ishan Verma, Alok Khaware, 23
rd
NCICEC, Surat, 13
th
-16
th
Dec
2011 ANSYS, Inc. December 19, 2013 24
Pressure- Traces
12
32
52
72
92
112
132
152
680 700 720 740 760 780
P
r
e
s
s
u
r
e
,

B
a
r
Crank Angle, deg
BASELINE Piston ONE Piston TWO Piston THREE
2011 ANSYS, Inc. December 19, 2013 25
2011 ANSYS, Inc. December 19, 2013 26
Cylinder Head Temperature Prediction
Temperature profile on
the firedeck
Time-averaged Heat
Flux profile on cylinder
head
Steady state conjugate heat
transfer of cylinder head
Transient in-cylinder
combustion simulation in
diesel engine
Iterative Process
2011 ANSYS, Inc. December 19, 2013 27
Solver Details
Dynamic Mesh (Layering) to account for piston and valve motion.
SST-kwmodel for turbulence modeling.
Discrete Phase Modeling for Sprays
Spherical drag model
Wall-film boundary condition
KH-RT breakup model
Solid-cone injection type
Turbulent dispersion of particles
Stochastic collision model
Temperature dependent liquid properties (especially vapor pressure and surface
tension)
Diesel Unsteady Flamelet Model (DUFL) with reduced n-heptane mechanism*
Solver Settings
Unsteady segregated solver with cell-based gradients
P-V Coupling : PISO
Pressure : PRESTO!
Transport Equations : 2
nd
order
* University of Wisconsin-Madison, Engine Research Center, n-heptane reaction mechanism (29
species and 52 reactions), SAE 2004-01-0558.
2011 ANSYS, Inc. December 19, 2013 28
Results
S. Shrivastava, P. Mandloi, A. Walavalkar 'Modeling IC Engine Thermal Management using ANSYS CFD' at IMEM
Users Group Meeting at the SAE Congress, April 23, 2012. Detroit, MI, USA
Transient IC runs performed on dual-quad core machine with 32
GB RAM and AMD 64 bit processors with 2.8 GHz clock-speed,
using 16 nodes.
2011 ANSYS, Inc. December 19, 2013 29
Summary
ICE System in Workbench provides a consistent and
easy-to-use workflow for setting up IC engine problem
Spray and Combustion Models cover a wide range of
applicability of engine systems and their operating
conditions
Case-Studies and Best Practices demonstrate the
validation of IC engine modeling capabilities in ANSYS
CFD
2011 ANSYS, Inc. December 19, 2013 30
Tutorials and Training Material
2011 ANSYS, Inc. December 19, 2013 31
27-29 Jan, 2014
ANSYS, Pune
2011 ANSYS, Inc. December 19, 2013 32
Coming up..
Port flow
Jacket filling
Jacket boiling
Thermal stress
Thermal fatigue
2011 ANSYS, Inc. December 19, 2013 33
Thank you!