A unified spray model for engine spray simulation using dynamic mesh refinement

This study is based on dynamic mesh refinement and uses spray breakup models to simulate engine spray dynamics. It is known that the Lagrangian discrete particle technique for spray modeling is sensitive to gird resolution. An adequate spatial resolution in the spray region is necessary to account for the momentum and energy coupling between the gas and liquid phases. This study uses a dynamic mesh refinement algorithm that is adaptive to spray particles to increase the accuracy of spray modeling. On the other hand, the accurate prediction of the spray structure and drop vaporization requires accurate physical models to simulate fuel injection and spray breakup. The present primary jet breakup model predicts the initial breakup of the liquid jet due to the surface instability to generate droplets. A secondary breakup model is then responsible for further breakup of these droplets. The secondary breakup model considers the growth of the unstable waves that are formed on the droplet surface due to the aerodynamic force. The simulation results are compared with experimental data in gasoline spray structure and liquid penetration length. Validations are also performed by comparing the liquid length of a vaporizing diesel spray and its variations with different parameters including the orifice diameter, injection pressure, and ambient gas temperature and density. The model is also applied to simulate a direct-injection gasoline engine with a realistic geometry. The present spray model with dynamic mesh refinement algorithm is shown to predict the spray structure and liquid penetration accurately with reasonable computational cost.     

Large eddy simulation of high pressure spray with the focus on injection pressure

This paper presents a detailed numerical analysis of diesel engine spray structure induced by the Engine Combustion Network (ECN) Spray A at different injection pressures. The non-reacting simulations are performed using OpenFOAM where an Eulerian–Lagrangian model is adopted in the large eddy simulation (LES) framework. Effects of the LES mesh resolution as well as the spray model parameters are investigated with the focus on their impact on spray structure as the injection pressure varies. The predicted liquid and vapour penetration lengths agree well with the measurements at different injection pressures. The mixture fraction is well captured for the injection pressure of 100 and 150 MPa while a slight deviation from the measurements is observed for the injection pressure of 50 MPa near the nozzle. The parametric analysis confirms that the LES mesh resolution has significant effects on the results. A coarser mesh leads to higher liquid and vapour penetration lengths where the deviation from the measurements is larger, resulting in the highest error at the lowest injection pressure. As the mesh size increases, the droplet size distribution becomes narrower, its pick moves to the smaller droplet size and the probability of droplets with higher temperature increases. On the other hand, with increasing the mesh size, the carrier gas velocity decays slower and its radial dispersion decreases. It is found that the droplet characteristics are more affected by the mesh resolution when the injection pressure is the lowest while the opposite is true for the carrier phase. The number of Lagrangian particles also affects the droplet characteristics and the fuel-air mixing but their effects are not as significant as the mesh size. The results become less sensitive to the number of Lagrangian particles as the pressure injection decreases. Finally, the importance of the initial droplet size distribution is investigated, confirming its impact is marginal, particularly on the liquid length. It is observed that the initial droplet size is only important at very close to the nozzle and its impact on the spray structure becomes quickly insignificant due to the high rates of breakup and evaporation. This trend is consistent at different injection pressures.     

Producing droplets smaller than the nozzle diameter by using a pneumatic drop-on-demand droplet generator

A pneumatic droplet generator to produce water/glycerin droplets smaller than the nozzle diameter is described. The generator consists of a T-junction with a nozzle fit into one opening, the second opening connected to a gas cylinder through a solenoid valve and the third connected to a length of steel tubing. The droplet generator is filled with liquid. Opening the valve for a preset time creates a pulse of alternating negative and positive pressure in the gas above the surface of the liquid, ejecting a single droplet through the nozzle. Droplet formation was photographed and the pressure variation in the droplet generator recorded. The effect of various experimental parameters, such as nozzle size, pressure pulse width and liquid properties on droplet formation was investigated. Small droplets could not be generated when liquid viscosity was too low or too high. For pure water, droplet diameters were several times that of the nozzle. Using more viscous glycerin mixtures, droplets with diameters as small as 65% of the nozzle diameter could be produced.     

Aerodynamic behavior of liquid sprays

An analysis is presented for the effect of entrained gas flows on drop trajectories and spray distributions from liquid atomizing nozzles. In particular, the effect of the pressure (or density) of the environment into which the liquid is sprayed is examined. The contraction of atomized sprays at elevated pressure which has been observed by various workers is explained, and the analysis is substantially confirmed by their data and by new data presented here. Both the data and the theory show that the amount of spray contraction increases with increasing ambient pressure and nozzle pressure drop, and decreases with increasing nozzle diameter and drop size. The theory examines the entrained gas flow around and into a spray and its subsequent effect on the trajectories of the liquid droplets comprising the spray.     

Evaluation of FFT-based cross-correlation algorithms for PIV in a periodic grooved channel

The design of a pneumatic droplet generator to produce small (~0.2 mm diameter) water droplets on demand is described. It consists of a cylindrical, liquid-filled chamber with a small nozzle set into its bottom surface, connected to a gas cylinder through a solenoid valve. Rapidly opening and closing the valve sends a pressure pulse to the liquid, ejecting a single droplet through the nozzle. Gas in the chamber escapes through a vent hole so that the pressure drops rapidly and more droplets do not emerge. We photographed droplets as they emerged from the nozzle, and recorded pressure fluctuations in the chamber. We determined the duration of the pressure pulse required to generate a single drop; longer pulses produced satellite drops. The length of the water jet when its tip detached and the diameter of the droplet that formed could be predicted using results from linear stability analysis. The peak pressure in the cavity could be increased by raising the supply pressure, increasing the width of the pressure pulse, or by reducing the size of the pressure relief vent.     

Effect of Droplet Size and Atomization on Spray Formation: A Priori Study Using Large-Eddy Simulation

The paper is mainly focused to the vast number of researchers who work within direct injection (DI) engine fuel spray simulations. The most common simulation framework today within the community is the Reynolds Averaged Navier Stokes (RANS) approach together with the Lagrangian Particle Tracking (LPT) method. In fact, this study is one of the first studies where high resolution LES/LPT diesel spray modeling is considered. The potential of LES to deepen the present day multidimensional LPT fuel spray simulations is discussed. Spray evolution is studied far from an injector by modeling a spray as a particle laden jet (PLJ). The effect of d on mixing in non-atomizing and atomizing sprays is thoroughly investigated at jet inlet Reynolds number Re?=?10⁴ and Mach number Ma?=?0.3. Based on and justified by rather recent and also quite old ideas, novel and compact views on droplet breakup in turbulent flows are pointed out from the literature. We use LES/LPT to illustrate that even in a low Weber number flow (We?<?13) the droplet breakup modeling may need considerable attention in contrast to what is typically assumed in the present-day breakup models. LES and LPT techniques are first applied to essentially confirm certain expected droplet size effects on spray shape in non-atomizing monodisperse sprays. In the simulations LES e.g. produces an expected turbulent dispersion pattern that depends on droplet diameter (d) without a droplet dispersion model in contrast to RANS. A new compact droplet breakup model is formulated and tested for droplets that break with a natural resonance time rate according to the Poisson process. As a result of the study: 1) the analysis gives a rigorous and enriching proof of currently existing views on droplet size effects on mixing, and 2) the presented a priori analysis points out the importance of modeling the resonance breakup even at a low We.     

Flow and atomization characteristics of a twin-fluid nozzle with internal swirling and self-priming effects

A twin-fluid nozzle was proposed for low-pressure atomization. The nozzle is featured by swirling air flows in the mixing chamber. Liquid medium is thereby inhaled due to the pressure difference. An experimental work was performed to investigate the atomization performance of the nozzle and the hydrogen peroxide solution served as the liquid medium. Droplet size and droplet velocity were measured. Effects of the diameter of the air-injection orifice and the air-injection pressure were investigated. The results show that small droplet size is achieved with the proposed nozzle. As the spray develops, Sauter mean diameter (SMD) of the droplets decreases first and then increases, irrespective of the variation of the air-injection orifice diameter and the air-injection pressure. Overall SMD varies inversely with the air-injection orifice diameter and air-injection pressure. Near the nozzle, cross-sectional velocity distribution exhibits a peak-valley pattern, which is replaced with uniformized velocity distributions away from the nozzle. Similarity of cross-sectional radial velocity distribution at different air pressures is evidenced. Furthermore, the correlation between droplet size and droplet velocity is established.     

Study on imaging method for measuring droplet size in large sprays

Information of droplet size and size distribution lays the basis for investigations of atomization mechanisms and performance optimization.However,the laser diffraction and phase Doppler particle analyzers have difficulty in accurately characterizing sprays with a wide range of droplet sizes and very large droplets,especially if a large number of droplets are aspherical.A method to measure size in such largedroplet sprays based on digital imaging with backward illumination was developed,including an image acquisition system and image process programs.Calibration of the measurement system was performed using a dot calibration target with different dot sizes.An experimental setup was designed and established to characterize spray nozzles under different operation loads,as well as different nozzle arrangements.Results show that the droplet size of sprays ranges from dozens of microns to several millimeters.The superiority of wide load range for such nozzles was indicated by the size-measurement results under half-load to full-load operations.The present study revealed that the image processing technique can be effectively implemented for in-line size measurements of sprays with a wide distribution of droplet size and aspherical droplets,which would be difficult to characterize by other methods.     

Study on imaging method for measuring droplet size in large sprays

Information of droplet size and size distribution lays the basis for investigations of atomization mechanisms and performance optimization. However, the laser diffraction and phase Doppler particle analyzers have difficulty in accurately characterizing sprays with a wide range of droplet sizes and very large droplets, especially if a large number of droplets are aspherical. A method to measure size in such large-droplet sprays based on digital imaging with backward illumination was developed, including an image acquisition system and image process programs. Calibration of the measurement system was performed using a dot calibration target with different dot sizes. An experimental setup was designed and established to characterize spray nozzles under different operation loads, as well as different nozzle arrangements. Results show that the droplet size of sprays ranges from dozens of microns to several millimeters. The superiority of wide load range for such nozzles was indicated by the size-measurement results under half-load to full-load operations. The present study revealed that the image processing technique can be effectively implemented for in-line size measurements of sprays with a wide distribution of droplet size and aspherical droplets, which would be difficult to characterize by other methods.     

A pneumatic droplet-on-demand generator

The design of a pneumatic droplet generator to produce small (~0.2 mm diameter) water droplets on demand is described. It consists of a cylindrical, liquid-filled chamber with a small nozzle set into its bottom surface, connected to a gas cylinder through a solenoid valve. Rapidly opening and closing the valve sends a pressure pulse to the liquid, ejecting a single droplet through the nozzle. Gas in the chamber escapes through a vent hole so that the pressure drops rapidly and more droplets do not emerge. We photographed droplets as they emerged from the nozzle, and recorded pressure fluctuations in the chamber. We determined the duration of the pressure pulse required to generate a single drop; longer pulses produced satellite drops. The length of the water jet when its tip detached and the diameter of the droplet that formed could be predicted using results from linear stability analysis. The peak pressure in the cavity could be increased by raising the supply pressure, increasing the width of the pressure pulse, or by reducing the size of the pressure relief vent.     

Application of maximum entropy method for droplet size distribution prediction using instability analysis of liquid sheet

This paper describes the implementation of the instability analysis of wave growth on liquid jet surface, and maximum entropy principle (MEP) for prediction of droplet diameter distribution in primary breakup region. The early stage of the primary breakup, which contains the growth of wave on liquid–gas interface, is deterministic; whereas the droplet formation stage at the end of primary breakup is random and stochastic. The stage of droplet formation after the liquid bulk breakup can be modeled by statistical means based on the maximum entropy principle. The MEP provides a formulation that predicts the atomization process while satisfying constraint equations based on conservations of mass, momentum and energy. The deterministic aspect considers the instability of wave motion on jet surface before the liquid bulk breakup using the linear instability analysis, which provides information of the maximum growth rate and corresponding wavelength of instabilities in breakup zone. The two sub-models are coupled together using momentum source term and mean diameter of droplets. This model is also capable of considering drag force on droplets through gas–liquid interaction. The predicted results compared favorably with the experimentally measured droplet size distributions for hollow-cone sprays.     

Breakup and atomization characteristics of mono-dispersed diesel droplets in a cross-flow air stream

This paper describes the microscopic and macroscopic breakup characteristics, as well as the velocity and size distributions, of mono-dispersed droplets in relation to the breakup regimes. For this experiment, a droplet generator equipped with a piezo stack produced mono-dispersed droplets. The droplet-breakup phenomenon due to the cross-flow was captured in microscopic and macroscopic views by using the following: a spark lamp, a Nd:YAG laser, a long distance microscope and a CCD camera as a function of the Weber number. Along with the analysis of the images, the droplet size and velocity distributions were measured in the near nozzle region by a phase Doppler particle analyzer system at bag, stretching and thinning, and catastrophic breakup regimes. The results of this study showed the size and velocity distributions of disintegrated droplets at the bag, stretching and thinning, and catastrophic breakup regimes. In the bag breakup regime, the droplets separated into small and large droplets during breakup. Alternatively, the droplets disintegrated at a shorter duration and formed a cloud, similar to a fuel spray injected through an injector, in the stretching and thinning and catastrophic breakup regimes.     

A study on the fuel injection and atomization characteristics of soybean oil methyl ester (SME)

The spray atomization characteristics of an undiluted biodiesel fuel (soybean oil methyl ester, SME) in a diesel engine were investigated and compared with that of diesel fuel (ultra low sulfur diesel, ULSD). The experimental results were compared with numerical results predicted by the KIVA-3V code. The spray characteristics of the spray tip penetration, spray area, spray centroid and injection delay were analyzed using images obtained from a visualization system. The Sauter mean diameter (SMD) was analyzed using a droplet analyzer system to investigate the atomization characteristics.It was found that the peak injection rate increases and advances when the injection pressure increases due to the increase of the initial injection momentum. The injection rate of the SME, which has a higher density than diesel fuel, is higher than that of diesel fuel despite its low injection velocity. The high ambient pressure induces the shortening of spray tip penetration of the SME. Moreover, the predicted spray tip penetration pattern is similar to the pattern observed experimentally. The SMD of the SME decreases along the axial distance. The predicted local and overall SMD distribution patterns of diesel and SME fuels illustrate similar tendencies when compared with the experimental droplet size distribution patterns.     

The use of single-point measurements to characterize dynamic behavior in sprays

In an effort to derive dynamic information from a single-particle counting device such as the phase-Doppler interferometer (PDI), a one-dimensional motion model and a sequential sorting algorithm have been developed to calculate the distance and velocity difference between consecutive droplets in sprays, as well as the number of droplets in close proximity (grouplets) and the frequency of grouplet formation. By focusing on sprays that are primarily uni-directional, this model can be used to highlight dynamic behavior and provide information that may indicate tendencies for clustering, collision, coalescence or evaporation among the droplets – information that is not available when considering the histograms of droplet size and velocity normally produced by PDIs. The motion model and sorting algorithm are validated for a mono-sized droplet stream generated by piezo-electric excitation, and are then applied to two other sprays to determine dynamic behavior. For a pressurized-liquid nozzle emitting water, the expected trends of droplet deceleration and spatial dispersion are found moving away from the exit of the nozzle, and significant in velocity differences between closely-spaced droplet pairs are observed. No dominant frequencies are present in the grouping of the droplets. For a droplet-laden air jet excited at a known frequency, similar results are calculated for droplet spacing, grouping and velocity differences, and the driving frequency is also obtained from analysis of the sequentially-sorted PDI data. Although the models developed assume an idealized PDI system, real operating characteristics of PDI systems place limits on the accuracy of these analyses. Received: 10 October 1998/Accepted: 5 October 1999     

Transient fuel spray impingement at atmospheric and elevated ambient conditions

This study analyses detailed temporally resolved full flow field data for pre- and post-impingement fuel sprays under atmospheric and elevated ambient conditions. A comprehensive suite of diagnostic techniques is utilised comprising of phase-resolved Phase Doppler Interferometry—employing a very fine grid and velocity signature to differentiate between pre- and post-impingement droplets—high-speed imaging (utilising Mie-scattering), high-magnification shadowgraphy and an adapted instantaneous mass-rate tube. Raised ambient conditions are achieved in a high-temperature, high-pressure constant volume rig affording large optical access. Temporal data for the free and impinging sprays is compared and analysed within three phases—early, mid and late injection—defined by the mass-rate tube data. All experimental techniques employed present consistent temporal and spatial trends at atmospheric and elevated ambient conditions, and global trends are consistent with the phenomenological flow structure originally proposed by Ozdemir and Whitelaw. Detailed analysis close to the piston surface reveals approximately a threefold increase in the D₅₀ mean spray diameter for the post-impingement droplet size distribution at the wall spray tip. It is suggested that this is due to droplet coalescence, with some supporting evidence from high-speed imaging. Comparison of transient mass deposited on the surface with model predictions show reasonable agreement with the ‘Wet’ model assumption.     

Modeling of droplet collision-induced breakup process

The present article proposes a new droplet collision model considering droplet collision-induced breakup process with the formation of satellite droplets. The new model consists of several equations to investigate the post-collision characteristics of colliding droplets and satellite droplets. These equations are derived from the conservations of droplet mass, momentum, and energy between before and after collision, and make it possible to predict the number of satellite droplets, and the droplet size and velocity in the analytical way. To validate the new collision model, numerical calculations are performed and their results are compared with experimental data published earlier for binary collision of water droplets. It is found from the results that the new model shows good agreement with experimental data for the number of satellite droplets. It can be also shown that the predicted mean diameter by the new model decrease with increasing the Weber number because of the collision-induced breakup, whereas the O’Rourke model fails to predict the size reduction via the binary droplet collision.     

泡沫镍/聚氨酯双连续复合材料的液滴冲蚀行为研究

利用液滴冲蚀试验装置,开展了泡沫镍/聚氨酯双连续复合材料和纯聚氨酯的液滴冲蚀试验研究,并采用PIV系统,测量了液滴冲蚀中液滴速度和直径. 结果表明:随着冲击能量的增加,复合材料表现出比纯聚氨酯更好的抗液滴冲蚀性能;泡沫镍结构参数对复合材料的液滴冲蚀行为有重要影响,泡沫镍孔径越小、体密度越大,复合材料的抗冲蚀能力越强;密集的金属骨架能有效阻挡高速液滴的破坏作用,并为树脂基体提供较强的阴影保护效应和地毯保护效应,显著提高复合材料的抗冲蚀性能.      

Experimental and analytical investigation of liquid sheet breakup characteristics

The main objective of this research is to study analytically and experimentally the liquid sheet breakup of a flat fan jet nozzle resulting from pressure-swirling. In this study the effects of nozzle shape and spray pressure on the liquid sheet characteristics were investigated for four nozzles with different exit widths (1.0, 1.5, 2.0 and 2.5 mm). The length of liquid sheet breakup, liquid sheet velocity and the size of formed droplets were measured by a digital high speed camera. The breakup characteristics of plane liquid sheets in atmosphere are analytically investigated by means of linear and nonlinear hydrodynamic instability analyses. The liquid sheet breakup process was studied for initial sinuous and also varicose modes of disturbance. The results presented the effect of the nozzle width and the spray pressure on the breakup length and also on the size of the formed droplets. Comparing the experimental results with the theoretical ones for all the four types of nozzles, gives a good agreement with difference ranges from 4% to 12%. Also, the comparison between the obtained results and the results due to others shows a good agreement with difference ranged from 5% to 16%. Empirical correlations have been deduced describing the relation between the liquid sheet breakup characteristics and affecting parameters; liquid sheet Reynolds number, Weber number and the nozzle width.