Week 9: Project 1 - Surface preparation and Boundary Flagging (PFI)

Aim: Surface preparation and Boundary Flagging (PFI)

Objective: The task to be performed are as follows

1 Boundary Flagging.

2 Surface preparation.

After setting up the NO HYDRO case set up, make sure you create an animation for NO HYDRO and send it to us on Freshdesk (support@skill-lync.com)

Make sure you are submitting a detailed report explaining the entire setup of NO HYDRO and showing all errors you came across and explain the meaning of each error.

Also, show the mesh on different slices at different time steps.

In an animation, all the valves and pistons should move accordingly to the crank angles and if it looks fine to us we will ask for the FULL HYDRO case set up.

We will run this FULL HYDRO case in our cluster and provide you with 3D OUTPUT FILES and Averaged output files so that you make use of them to post-process the results and get required plots respectively.

Introduction

Fuel injection is the introduction of fuel in the internal combustion engine most commonly automotive engines by the means of an injector. Port fuel injections long ago replaced carburetors in cars because of their efficiency and lower maintenance requirements.

The fuel injector is installed in the intake manifold and they are cheap in production and do not have to withstand high pressure from the combustion chamber. The fuel injector injects the fuel into the combustion chamber through the intake valve owing to which the intake valve always remains and there is no carbon deposit in the intake valve. The major disadvantage with respect to the other injection system is that it lacks efficiency (better fuel economy) with respect to the other fuel delivery system.

Surface preparation and Boundary flagging

The geometry is loaded into the Converge-CFD environment and the diagnosis dock is selected. It was found that there are a lot of errors viz Intersections(1574), Non manifold Problems(5), Open Edges(32), Normal orientation(214). Therefore boundary flagging is required to hide the parts of the boundary to resolve all of the errors.

Piston

The piston boundary is selected by using the angle method from the boundary.

Inflow

The inflow boundary is selected by using the angle method

Liner

The liner is selected by using the boundary fence method, because by using the angle method the portion of the liner, cylinder head, and the piston is selected. Therefore from the Geometry dock, "Fence" is selected and the "Arc" method is selected from the top ribbon to flag the "Liner" using the "Boundary Fence" method.

Cylinder head

The cylinder head is selected by creating the fence around the intake and exhaust port, the other fence is already created from the "Liner". The same is flagged by sing the "Boundary Fence" method. From the below snap it can be inferred that the intake valve is so high that it is interfering with the cylinder head which forms the basis of intersection errors. In order to fix these, the valve is pushed downwards to remove the intersection errors.

Exhaust port and Outflow

The exhaust port and the outflow are flagged by using the "Angle" method. After flagging, the two boundaries are hidden to visualize the parts of exhaust valves.

Exhaust valve top, Exhaust valve angle, Exhaust valve bottom

The fences are marked as shown below to divide the exhaust valve into three boundaries. Once the boundaries are hidden there are extra pieces that are visible which needs to be part of the exhaust port boundary. Thus "Box Pick" option is selected from the top ribbon and the extra pieces are selected and flagged under the exhaust port boundary. The ring triangles need to be part of the exhaust port. The extra pieces and the ring triangles are shown below.

Extra Pieces

Ring Triangle

Intake port

In order to select the "Intake port" the fence method is used. In the "Geometry" dock the "Fence" tab is selected and "Reconstruct Fences From Existing Boundaries" is selected which will create the fences automatically from the Inflow and the fences at the end of the intake port which is near to the cylinder head. The area is flagged by using the "Boundary Fence" method.

Intake valve top, Intake valve angle, Intake valve bottom

The boundary fences already exist for the intake port. The new boundary fences are created for the intake valve bottom, intake valve angle, intake valve top. The bottom region of the valve is selected by using the "Angle" method. In order to select the angle portion of the valve, the fence is created at its two ends. The remaining portion is flagged to the Intake valve bottom by using the option "Reconstruct Fences From the Existing Boundaries". The Intake valve bottom and angle boundaries are hidden so that the portion which is left to flag is the Intake valve top boundary.

The new fence is created for the Intake valve top boundary as shown below and the "Boundary Fence" is selected to flag the boundary.

Spark plug and Spark terminal

The Spark terminal is selected by using the Angle method. The fence is created around the Spark terminal by using "Reconstruct Fences From Existing Boundaries". The base of the Spark plug is marked for fencing. The Spark plug is flagged by using the "Boundary Fence" option method. The reason to flag them as separate boundaries because they are set at different temperatures. 

Intake port-2

The Intake port boundary is split into two boundaries, the main reason being is to create the Events. The Intake port is closest to the valves and Intake port-2 is closest to the Inflow boundary where the species air is entering into the Engine.

Resolving Errors

Intersection Errors

The triangles of the intake port are intersecting with the triangles of the cylinder head. In order to resolve this "Measure" tab is selected under which the "Arc normal" is selected. The three vertex points are selected from the intake valve (need to make sure that the vertex points lie on the same circle). The "Apply" button is selected and the "Arc normal" is obtained. The "Transform" tab is selected in which the "Translate" option is there and the following variables are written down in the dialogue box.

The "Selected Boundary" option is enabled and the Intake valve top, Intake valve angle, Intake valve bottom boundaries are selected. The Diagnosis is done for the geometry it was found that the Intersection Errors has come down to 3.

Open Edges

The area is open and as the Converge works on the finite volume method therefore it detects the open edges and expects us to fix that.

In the "Geometry" dock select Repair and the Patch tab is selected. The Free edge loop (pick exactly one edge) is selected. The method "By Open Edge" is selected from the main ribbon and the problem is rectified. Once the open edges are converted into triangles the error comes down to 0. 

The diagnosis is again run for the geometry and it is found that Intersection Errors, Open Edges, Non-manifold errors are 0.

Normal orientation

The normal vector should point inside the control volume not outside. Therefore in order to fix that the "Transform" option is selected and the "Normal" tab is hit. The triangle is selected and the normal vector is selected which is pointing outwards and then hit on apply.

Once these errors are resolved the diagnosis dock is clean.

Case-setup

The crank angle-based IC engine application type is selected.

Under "Gas simulation" the Equation of state is selected as "Redlich Kwong", the critical temperature is 133K and the critical pressure is 3770000Pa and the therm.dat file is loaded under Gas thermodynamic data. The Turbulent Prandtl number is 0.9 and the Turbulent Schmidt number is 0.78 under Global Transport parameters. The PFI engine involves the combustion process therefore the Reaction mechanism is selected and mech.dat is loaded. Under Run parameters, the parameters are kept at their default values except the Simulation mode is selected as No hydrodynamic solver (for testing setup only). Under Simulation time parameters start time is -480 deg, end time is 240 deg. The initial time step is 1e-07s and the minimum time step is 1e-08s. The maximum time step is 0.0001s and the rest values are kept as default. The Solver parameters are kept as default.

Boundary selection

The boundary selection and their parameters are tabulated as under

 Species information at the Outflow boundary

Combustion of iso-octane will yield carbon dioxide, water, and nitrogen at the outlet.

`C_8H_18+12.5(O_2+3.76N_2) to 8CO_2+9H_2O+(3.76**12.5)N_2`

The combustion is stoichiometric which means if we place the right amount of fuel corresponding to that the right amount of end products are obtained.

Regions and initialization

The regions with parameters are tabulated below

Events

Events are created between the regions to regulate the flow between them. As the Events are activated between the regions the Converge creates a disconnect triangle between them. Please note that these triangles are virtual triangles and should not be created by the user. Events can be cyclic, sequential, and permanent.

Cyclic 

Permanent

Setting up of Turbulence model

The Realisable `k-epsilon` model is selected from the case-setup tree for the above-said simulation. Since the size of the eddies is restricted near the wall and the maximum size of the eddies is formed away from the wall. It is well suitable for resolving flows in the logarithmic flow region where y+ ranges from 30 to 300 and flow involving a high Reynolds number.

Base grid

The element size of 4e-3 was selected which is the default base grid.

Mesh on slices

Results

Mesh animation

PFI Engine animation

Conclusion

• The PFI surface preparation and the boundary flagging were done successfully using Converge-CFD and Cygwin command prompt terminal.
• The errors were obtained after the Diagnosis was removed successfully and set up for simulation.
• The no-hydrosimulation setup was done successfully and the animation of the PFI Engine was uploaded successfully.
• Fixed embedding was not used in the simulation setup as such the software uses an academic license and the use of the fixed embedding exceeded the number of cells that is 5,12,000 cells.
• The species information, the profile were uploaded successfully in their respective domain.