Modeling A Fuel Injector For A Two
Modeling A Fuel Injector For A Two
SOCHACZEWSKI, R., CZYŻ, Z., SIADKOWSKA, K. Modeling fuel injector two-stroke diesel engine. Combustion Engines. 2017,
170(3), 147-153. DOI: 10.19206/CE-2017-325
Table 2. Simulation parameters We modeled a valve closes orifice nozzle of a real ge-
Rotational Mean cylin-
ometry in which its efficient flow field is calculated from
Type of Power Fuel mass the height of the nozzle needle. The coefficient of through-
speed der pressure
operation
[rpm] [kW] [mg/cylinder] [MPa] the-injector-hole-flow loss is as 0.83, given that a correla-
idle 1000 1.6 3.2 5.30 tion of an edge rounding and a hole diameter as r/d = 0.2
max. load 4000 100 29 11.65 [8]. A control valve was modelled as a throttle in which the
flow field is a function of time. In cooperating elements like
To achieve a favorable air-fuel mixture, i.e. the largest a needle with a nozzle body and a control piston with a
possible contact surface of fuel injected with air, the fuel is cylinder, there is assumed a loss due to fuel leaks. The
assumed to be injected with one or two injectors of the model of fuel leaks is based on the Hagen-Poiseuille law,
number of nozzle holes as in Table 3. given a laminar flow through Annular Gap which changes
according to fuel pressure [3].
Table 3. Options of the number of nozzle holes
A given amount of fuel is injected by estimating the
Number of injectors per Number of nozzle holes minimum flow field for assumed parameters of injection
combustion chamber 2 3 4 6 and properties of the fuel. This is possible using sophisti-
1 ● ● cated hydraulic models [14]. Approximate dependence was
2 ● ● ●
used in the studies [13]:
m c ⋅ A ⋅ 2 ⋅ ρ ⋅ Δp (1)
3. Model of an injector
Our research uses a Common Rail system injector de- where m fuel mass flow rate [mg/cycle], cd – outflow
sign controlled with a solenoid valve because of the overall coefficient, An – minimal flow field [mm2], ρf – fuel density
dimensions of the injector that define its weight and the [kg/m3], Δp = (p2 – p1) – pressure difference [MPa], p1 –
ease of installation and arrangement of injectors on the combustion chamber air pressure, p2 – injected fuel pressure.
engine. Fig. 3 depicts a model of the injector created in the The relationship was transformed to the following formula
Boost Hidsim. for the minimum injection field of a single nozzle hole:
4. Research results
Fig. 7. Flow area (4-hole nozzle, t1 = 0.4 ms; d4 = 0.16 mm) at injection
4.1. Idle times of a main fuel dose t2 = 0.5; 0.6; 0.7 ms
One injector
Given the values of the parameters and the calculated Table 5. Simulation for a 4-hole nozzle
hole diameters, the minimal injection time when the injec- Injection
Hole Required
tor completely opens was calculated. An outflow is limited diameter
times of Minimum Calculated
fuel
Calculated
main fuel flow area flow area fuel mass
by a field of injector hole but not the gap between the nee- d4
dose t2
mass
dle and the seat in the nozzle. The injector will not operate [mm] [ms] [mm2] [mm2] [mg] [mg]
within a range of ballistic amounts of fuel. There are the 0.50 0.02584 2.44
research results of the injector operating in idling condi- 0.14 0.60 0. 01485 0.03157 3.20 3.35
0.70 0.03562 4.35
tions. The maximum efficient flow field was compared
0.50 0.02926 2.71
(Fig. 5 and Fig. 7) to the flow field due to the injector hole 0.16 0.60 0. 02186 0.03643 3.20 3.73
diameter and the fuel mass per injection (Fig. 4 and Fig. 6). 0.70 0.04173 4.87
Table 5 and 6-hole nozzles.
4 holes Given the diameters as d4 = 0.14 and 0.16 mm and in-
jection times of main fuel doses as t2, the flow field is min-
imal in the assumed range. This means that the main doses
are injected within a non-ballistic range. At the same time,
if injecting the pilot dose t1 = 0.40 ms and the main dose
t2 ≈ 0.60 ms, the required dose at idle is achieved.
6 holes
Given the diameters d6 = 0.12 and 0.14 mm and inject-
ing the main fuel doses of t2, the flow field is minimal in
the assumed range. This means that the main doses are
injected within a non-ballistic range. At the same time, if
Fig. 4. Fuel mass (4-hole nozzle, t1 = 0.4 ms; d4 = 0.14 mm) at injection injecting the pilot dose t1 = 0.40 ms and the main dose
times of a main fuel dose t2 = 0.5; 0.6; 0.7 ms t2 ≈ 0.5–0.60 ms, the required dose at idle is achieved.
The simulation results are given in Fig. 10, Fig. 11 and Due to the large mass flow rates (d6 = 0.12 mm) for the
Table 10. diameter nozzle d6 = 0.14 mm, injection pressure was re-
duced to 120–140 MPa.
Fig. 10. Fuel mass (4-hole nozzle, t2 = 1.0 ms; d4 = 0.14 mm) at injection
pressures as p = 140, 160, 180 MPa Fig. 13. Fuel mass (6-hole nozzle, t2 = 1.0 ms; d6 = 0.14 mm) at injection
pressures as p = 140, 160, 180 MPa
Fig. 14. Fuel mass (2-hole nozzle, t2 = 1.0 ms; d2 = 0.14 mm) at injection
pressures as p = 120, 140, 160 MPa
Fig. 15. Fuel mass (2-hole nozzle, t2 = 1.0 ms; d4 = 0.16 mm) at injection Fig. 17. Fuel mass (4-hole nozzle, t2 = 1.0 ms; d42 = 0.10 mm) at injection
pressures as p = 120, 140, 160 MPa pressures as p = 120, 140, 160 MPa
Table 12. Simulation for a 2-hole nozzle Table 14. Simulation for a 4-hole nozzle
Hole Required fuel Calculated fuel Hole Required fuel Calculated fuel
Fuel pressure Fuel pressure
diameter mass mass diameter mass mass
[mm] [MPa] [mg] [mg] [mm] [MPa] [mg] [mg]
120 13.39 120 14.91
0.14 140 14.72 0.10 140 14.50 16.35
160 15.99 160 17.71
14.50
100 14.97
0.16 120 16.73 Summary
140 18.40 Two options of injection were investigated while mod-
eling an injector. For an input parameter, i.e. the fuel mass
A mass of injected fuel for the 3-hole nozzle of a hole required at idling and the maximum load, the assumption is
diameter of d3 = 0.12 mm and injection pressures as p = that the fuel is injected into the cylinder with one or two
120, 140, 160 MPa (Fig. 16) was calculated At the maxi- injectors. Depending on the option, the number of nozzle
mum load, the required dose is achieved at the injection holes was assumed to be from 2 to 6 so the number and
pressure of 120 MPa. For higher pressures, main dose injec- diameter of hole nozzles for the options were determined as
tion time should be reduced (Table 13). follows:
a) one injector
− a 4-hole injector of a hole diameter as d4 = 0.14 mm
or optionally d4 = 0.16 mm at reduced injection
pressure or time,
− a 6-hole injector of a hole diameter as d6 = 0.12 mm
b) two injectors
− 2-hole injectors of a hole diameter as d2 = 0.14 mm,
− 3-hole injectors of a hole diameter as d3 = 0.12 mm,
− 4-hole injectors of a hole diameter as d4 = 0.10 mm.
Fig. 16. Fuel mass (3-hole nozzle, t2 = 1.0 ms; d3= 0.12 mm) at injection The research results will be used to create the geometry
pressures as p = 120, 140, 160 MPa to develop nozzles for a given fuel injector to perform
bench tests. Such research will enable us to determine the
Table 13. Simulation for a 3-hole nozzle
mass flow rate and characteristics of the injectors. The mass
Hole Required fuel Calculated fuel flow rated calculated will be entered into the AVL Fire to
Fuel pressure
diameter mass mass
[mm] [MPa] [mg] [mg] optimize the combustion process.
120 15.40
Acknowledgement
0.12 140 14.50 16.92
160 18.36 This work has been realized in the cooperation with The
Construction Office of WSK "PZL-KALISZ" S.A." and is
4 holes part of Grant Agreement No. POIR.01.02.00-00-0002/15
It was calculated a mass of injected fuel for the 4-hole financed by the Polish Nation-al Centre for Research and
nozzle of the hole diameter of d42 = 0.10 mm and injection Development.
pressures as p = 120, 140, 160 MPa (Fig. 16). At the maxi-
mum load, the required dose is achieved at the injection
pressure of 120 MPa. For higher pressures, main dose injec-
tion time should be reduced (Table 13).
Rafał Sochaczewski, DEng. – Faculty of Mechanical Zbigniew Czyż, MEng. – Faculty of Mechanical
Engineering at the Lublin University of Technology. Engineering at the Lublin University of Technology.
e-mail: R.Sochaczewski@pollub.pl e-mail: Z.Czyz@Pollub.Pl