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
• 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 3
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 4
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 5
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

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 6

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

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 7

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 8
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
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 9
Demonstration : Direct Injection Gasoline Engine

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

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 10

Demonstration : Direct Injection Gasoline Engine
• Simulations
– Cold flow run
– Charge motion
• Plus spray injection
• Plus particle tracking
– Combustion
• Plus ignition
• Plus flame front propagation

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 11

Demonstration : Direct Injection Gasoline Engine
• Cold flow simulation
– Results for CFX and Fluent
– Cylinder averaged values of pressure and temperature

Wednesday, October 10, 2012 12

Demonstration : Direct Injection Gasoline Engine
• Cold flow simulation
– Results for CFX and Fluent
– Swirl ratio, tumble ratio

Wednesday, October 10, 2012 13

Demonstration : Direct Injection Gasoline Engine

• Velocity CA 330 CA 440

vector plots

CA 555 CA 715

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Demonstration : Direct Injection Gasoline Engine

• First injection

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Demonstration : Direct Injection Gasoline Engine

• Evaporation

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Demonstration : Direct Injection Gasoline Engine

• Second injection

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 17

Demonstration : Direct Injection Gasoline Engine
• Total particle mass
• Influence of wall film model
 Demonstration : Direct
Injection Gasoline Engine

• Combustion simulation

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 19

Demonstration : Direct Injection Gasoline Engine
• Burned flow simulation
– Cylinder averaged values
• Pressure
• Temperature
• Mixture fraction

20
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress
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 21
Validation: Particle Tracking
• Particle injection • Testcases
– Primary / secondary breakup – Bosch spray box (cold spray)
– Injection type: cone / hollow – Hiroyasu spray box (cold spray)
cone – 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 Setup # 2
Gas param eters
Gas type N2
Temperature [K] 300
0.00275 m
Pressure [MPa] 0.11 0.56
Fuel Properties sampling point
Fuel type Heptane 0.03 m (0, 0.00275, 0.03)
Density [kg/m3] 614.2
Surface tension [kg/s2] 0.0201
Spray parameters Available data
Initial temperature [K]
Nozzle diameter [mm]
300
0.151
• Spray penetration over time
Injection pressure [MPa]
Injection velocity [m/s]
10
138
• Sampling point (0, 0.00275, 0.03)
Particle mass flow rate [g/s] 1.5 - Droplet diameter distribution
Injection rate, single pulse [ms] 1.5
Estimated initial spray angle [deg] 5.2 12 - Droplet velocity distribution
Injection Weber number 85 450

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.
 Validation: Bosch Spray Box
• Mesh dependence study
Size of the cell near the
Number of
Grid nozzle [m 2]
cells
(radial x axial length)

Coarsest 364 12.8e-4 x 12.8e-4

Coarse 735 6.4e-4 x 6.4e-4

Medium 1450 3.2e-4 x 3.2e-4

Fine 2880 1.6e-4 x 1.6e-4

Finest 5824 8e-5 x 8e-5

Coarsest Coarse Medium Fine

Finest

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 24

Validation: Bosch Spray Box

• Mass penetration
• Mesh dependence study
• Fluent simulation
• Setup #2

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 25

Validation: Bosch Spray Box
• Local spray results at
sampling point
– Droplet diameter
distribution
– Local velocity distributions
– KH-RT breakup model
– Setup #1
Validation: Bosch Spray Box
• Local spray results at
sampling point
– Droplet diameter
distribution
– Local velocity distributions
– KH-RT breakup model
– Setup #2
Validation: Bosch Spray Box

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

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 28

Validation: Bosch Spray Box

• Mass penetration
• Comparison of break-up models
• CFX simulation
• Setup # 2 E xperiment
0.1 No breakup
R eitz &D iwakar
Penetration Depth [m] S chmehl
T AB
0.08 E T AB
C AB

0.06

0.04

0.02
Medium grid (4000 nodes)
dt = 2e-6 s
00 0.0005 0.001 0.0015 0.002
Time [s]
 Validation: Hiroyasu Spray Box
Case 1 Case 2 Case 3
Gas parameters

Gas type N2
Temperature [K] 300 300 300
Pressure [MPa] 1.1 3.0 5.0
Fuel Properties

Fuel type C12H26

Density [kg/m3 ] 840
Surface tension [kg/s2] 0.0205
Spray parameters

Initial Temperature [K] 300 300 300

Injection Velocity [m/s] 102 90 86
Particle Mass Flow 6.05 5.36 5.13
Rate [g/s]
Nozzle diameter [mm] 0.3 0.3 0.3
Injection rate, single 2.5 4 4
pulse, ms
Validation: Hiroyasu Spray Box

• Mass penetration
• Case 1, 2 and 3
• Fluent simulation
 Validation: Koss Spray Box
Gas Temperature [K] 800
Gas Pressure [MPa] 5
• Evaporating spray
Gas Type N2 – Liquid penetration at 90%
Particle Mass Flow Rate [g/s] 4.62
spray mass fraction
Droplets type nHeptane
(C7H16)
Density [kg/m3] 684
Surface tenstion [N/m2] 0.02
Nozzle diameter [mm] 0.2
Injection rate [ms] 1.3

Droplet diameter [mm] 0.2

Injection Velocity [m/s] 215
Initial spray angle [deg] 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.
Validation: Koss Spray Box
• Breakup model comparison
– TAB
– ETAB
– CAB
– Reitz
• CFX run

Wednesday, October 10, 2012

Validation: Koss Spray Box
• Comparison
– Fluent KH-RT
model
– CFX TAB model

Wednesday, October 10, 2012

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 35
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)
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 36
Validation: Hamamoto Testcase
• Average cylinder pressure
– Mesh sensitivity study Fluent, 2d quad meshes
– Comparison CFX vs. Fluent
Validation: Hamamoto Testcase
• Average cylinder pressure
– Comparison of mesh size and types
– 3D hexahedral and tetrahedral meshes
Combustion Validation: Pancake Engine
• Premixed combustion Displacement [m3] 0.82 x 10-3
• Flat head, flat piston, SI ICE
Bore x Stroke [mm] 105.0 x 95.25
• Fuel: C3H8
• References: Compression ratio 8.56
– Alkidas (1980)
– Han and Reitz (1997) Connecting rod length [mm] 158

• Simulated interval [-30;30 CA] ATDC TDC clearance [mm] 12.6

• Piston motion
Equivalence ratio 0.87

Engine speed [rpm] 1500

Spark timing [deg. ATDC] -27

Volumetric efficiency 40

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 39

Combustion Validation: Pancake Engine

• Average cylinder pressure

• G equation combustion
• Comparison
– CFX
– Fluent

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 40

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 41
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

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 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
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 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 132 mm

Inner port diameter 16 mm
Outer port diameter 34 mm
Valve opening 10 mm
Cylinder length 300 mm
Cylinder diameter 120 mm

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 44

ICE Validation: Port Flow

• Comparison
– RANS  SST model
– LES  SAS model
• CFX results

Isosurface S 2  2  106
Color – eddy viscosity
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 45
ICE Validation: Port Flow

• Plane @ 20 mm

• Mean Axial Velocity • Axial Velocity

Fluctuation
ICE Validation: Port Flow

• 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 In-
Cylinder 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 – PIV’11, Kobe, Japan, July 21-23, 2011
 Validation: Bosch Engine
• RANS simulation
– Flow characteristics  swirl
 
z  V  v dV
r
Rs   2
2 N  dV
r
V

4
Swirl Ratio [-]

1 Average swirl on planes

Simulation
Experiment (plane data)
Experiment
0
SwirlICE
CFX ration in cylinder
Swirl
-1
360 450 540 630 720
[cad]
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 49
Validation: Bosch Engine
• Scale Resolving Models
– LES – Large Eddy
Simulation
– DES – Detached Eddy
Simulation
– SAS – Scale Adaptive
Simulation
• Grid size:
– 1.2 – 6.8 · 106 nodes

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 50

Validation: Bosch Engine
• 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

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 52

Validation: Wisconsin Engine
• Riccardo Hydra Base
• Modern DISI engine architecture

Engine Specifications
Engine Type 4-Stroke, 4-Valve, SI

Chamber Geometry Pentroof

Fueling type Spray-guided direct-

injection
Displacement 692.9 cm3
Single-cylinder direction-injection Compression Ratio 12:1
spark-ignition engine used for
measurements Injection Pressure 11 MPa
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 53
Validation: Wisconsin Engine
• 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
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 54
 Validation: Wisconsin Engine
• Motored Engine Measurements
• Repeatability • Influence of coolant
2
temperature
Cylinder Pressure [bar]

10
8
6
4

1
8
6
4

5 6 7 8 9 2 3 4 5 6 7 8 9
0.1 1
Volume [L]

In-cylinder pressure for 2000 rpm 80

kpa, 80 oC intake, 80 oC coolant
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 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 User’s Group Meeting
2010 (IMEM 2010), Detroit, April 12th, 2010
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 56
Validation: Ducati Engine
• Simulation with CFX
– Efficient multi-cycle methodology
• Single-cycle initialization / multi-cycle initialization
– Influence of mesh resolution & types

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 57

 Validation: Ducati Engine
• Simulation with Fluent
– Variation of combustion models / turbulent flame
speed models and settings
140

cylinder pressure [bar]

10000 rpm -
Cyl_Horiz
10000 rpm -
120 Cyl_Vert
ECFM - cycle 1

C-eqn - cycle 1
100
EXP. MEAN IN-CYLINDER PRESSURE [bar] G-eqn - cycle 1

80 G-eqn zcd - cycle 1

G-eqn p - cycle 1

60 G-eqn pc - cycle 1

40

20
Average

0
-360 -270 -180 -90 0 90 180 270 360

-20
Crank Angle [deg]
CRANK ANGLE [deg. ATDC]

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 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

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 59

 Validation: Engine Cooling Simulation
Transient combustion
Steady state conjugate heat simulation in diesel engine
transfer of cylinder head in-cylinder

Time-averaged Heat
Flux profile on cylinder
head

Iterative Process

Temperature profile on
the firedeck
Validation: Engine Cooling Simulation
Import: temperature data

Iteration process

Export: time-averaged
heat flux from IVC to EVO
 Validation: Engine Cooling Simulation
• Heat Flux
• n-heptane 1
step
mechanism
y+~ 200 y+~ 30
• Effect of
mesh
resolution

y+~ 20 y+~ 1

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 62

 Validation: Engine Cooling Simulation
• Heat Flux K-epsilon K-epsilon
• n-heptane 1
step
mechanism
• Effect of Laminar Finite Rate Finite Rate - Eddy

combustion
SST K-w SST K-w
and
turbulence
model
Laminar Finite Rate Finite Rate - Eddy
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 63
Validation: Engine Cooling Simulation

• Temperature data at locations of thermocouples

– Heat Flux n-heptane 1 step mechanism + SST k
model (Laminar Finite Rate)

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 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
Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 65
Any Questions ?

Wednesday, October 10, 2012 2012 Automotive Simulation World Congress 66