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PDA Data Analysis for Near Injection Region of 3-Hole Gasoline Direct Injector

Technical Report · November 2011

DOI: 10.13140/RG.2.2.22362.36804

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Muhammad Mahabat Khan

Capital University of Science & Technology
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PDA Data Analysis for Near Injection Region of
3-Hole Gasoline Direct Injector

Prepared by

Muhammad M Khan
PDA Analysis Details

The injector used for the PDA

analysis is a 3 Hole, 90°, GDI
Injector.

95 Ron gasoline fuel is used at 100

bar line pressure and 2 ms fuel
injection period @ 9 mg/ms with 1
bar counter Pressure.

Radial Positions (R) and Axial

positions (Z) are used with respect
to the injector axis. These must not
be confused to with axial and radial
components of the plume

Fig. PDA data at different locations used for analysis

 3 Hole GDI Injector Geometry – PDA Alignment
Time After Electronic
Start of Injection ACTIONS
0 to 1.0 ms solenoid pre-charge
electronic-hydraulic response time and
1.0 to 1.2 ms transit time to Z = 3 mm
1.2 to 1.8 ms transient leading edge
2.0 to 3.0 ms ‘steady state’ fuel delivery
3.0 to 3.8 ms needle closes and spray decays
3.8 to 4.1 ms needle bounce

Table: Operational Time of the injector

1. Raw Data Analysis
Raw PDA Data Profiles at Z= -5mm and R=-6

Axial
Radial
Velocity
Velocity

Needle
steady injection Bounce

Needle Closure

Needle bounce
produces very big
droplets whose
Sometimes a few blobs appear in the early Diameter effect can be seen
stages of injection. Usually the size of these further downstream
blobs is between 70-100 microns. These few
blobs can change the diameter distribution
completely due to their massive size. These
blobs are captured in both 1D and 2D PDA
measurements. These blobs eventually
produce big droplets which may penetrate far.

These blobs were also confirmed by Dr.

Graham who took the measurements.
Downstream Evolution of Early injection Blobs

z=-3mm z=-5mm z=-10mm

Fig. Plots of Diameter vs Time

The blobs in the early part of injection are visible at the 3mm and 5mm measurements but at
10mm these blobs have been broken down to smaller droplets.
The needle bounce effect has not been minimized greatly at 10mm mark and very large droplets
are still visible at the centre of plume.
PDFs of Droplet Diameter along the Different Radial Position z=-5mm (t=2-2.5ms)

In the beginning, the PDF of diameter increases until R= -6. Then the diameter starts to reduce. That means center of
the plume is at R= -6.
Radial velocity along the Different Radial Position at z=-5mm at (t=2-
2.5ms)
Axial velocity along the Different Radial Position at z=-5mm at (t=2-
2.5ms)
3. Diameter Analysis
Diameter analysis along the Different radial position at Z=-5mm (t=2-
2.5ms)

Without Early With Early

Z = 5 mm
R = 6 mm Injection Blobs Injection Blobs

SMD and D90 confirms the fact that bigger

droplets at the centre of the plume.

The total width where significant amount of

bigger droplets are observed is around 3mm.

The Figures on the right show the effect of

early injection blobs. There is an offset of

around 7 and 20 microns in SMD and D90

respectively with only two blobs.

There is certainly some big droplets at R=-7.5mm. D90 captures this effect but SMD
doesn't..
Droplet Diameter Averaging at Z=-5mm (t=2-2.5ms)
Various Diameter averages at Z=5mm (t=2-2.5ms)

D31
D21 18
SMD 16
D90
14

Diameter (microns)
12 Z=-5mm
10
8
6
4
2
1
0  N 9 9
 D 
 i 
D =  i=1
-9 -8 -7 -6 -5 -4 -3 -2
Radial Positions 90

N 
 
 
 N 3
Different techniques for diameter averaging are used.  D 
 i 
SMD → D =  i=1  (Mass transfer )
32 N
  D2 
D90 is used to locate the bigger droplets in the plume.  
 i=1 i 
1
SMD is volume to surface ratio. It is very useful to study mass transfer  N 3 2
 D 
 i 
Length Mean → D =  i=1  (Evaporatio n )
31 N
D31 is volume to length ratio. It is used for the evaporation.  D 
 
 i=1 i 
 N 2
D21 is the measure of the absorption of the droplets. It is simply surface area  D 
 i 
Length Mean → D =  i=1  (Absorption )
21 N
to length ratio.  D 
 
 i=1 i 
4. Velocity Analysis
Mean Axial Velocity and RMS velocity at Different Axial
Positions (t=2-2.5ms)
Z=-3mm

Z=-3mm
Z=-5mm
Z=-5mm

Z=-7.5mm

Z=-10mm

Z=-7.5mm

Figure: Different Radial profiles of axial velocity

Kinetic Energy of Droplets at different Radial Positions (Z=-5mm t=2-
2.5ms)

R=4.5mm R=6mm R=8.5mm

(periphery) (Plume centre) (periphery)

Droplets momentum analysis gives the true picture of the

   D 
3

KE =   fuel     Vdrop
dominant droplets which drive the spray. 1 4 drop 2

Droplets less than 5 microns have negligible momentum and 2  3  2  

kinetic energy. Droplets more than 10 microns have   
comparatively very high momentum and energy.  4  Ddrop  3 
Mometum =  fuel     Vdrop
 3  2  
Relatively large scatter in the periphery is observed due to
the presence of strong shear.
Kinetic Energy and Momentum Profiles at Different Radial Positions (Z=-
5mm t=2-2.5ms)
Axial Kinetic energy at different Axial Kinetic energy at different
Radial Positions Radial Positions
1.50E-06 4.00E-08

Momentum Sum (Kg

Kinetic Energy
Sum (N.m)
1.00E-06 3.00E-08

m/s)
2.00E-08
5.00E-07
1.00E-08

0.00E+00 0.00E+00
-8.5 -7.5 -6.5 -5.5 -4.5 -3.5 -8.5 -7.5 -6.5 -5.5 -4.5 -3.5
Radial Positions Radial Positions (m m )

Kinetic energy & momentum, at the centre of plume, is higher due to the presence of very fast droplets. This
is clear when the effect of droplets is removed.
4. Droplets Distribution Analysis
Droplet Diameter Distribution Function
Modified Rosin Ramler distribution function is used to reproduce droplet distribution profiles (PDFs) of
PDA data
q D   D q 
q −1

PDF → QPDF =   exp−   

X X   X  
  D q 
CDF → QCDF = 1 − exp−   
  X  
where Q is the fraction of mass greater than D, D is the droplet diameter, X is the mean diameter, q is the spread
factor.

Spread Factor q=2 has been found to be true for all near nozzle measurements. This factor needs little bit tuning if
the measurements are away from the nozzle. The values varies from q=1.4 -2 for all cases.

CDF is cumulative distribution function, is easier way to see what PDF presents. It is very useful in locating the
percentage of a droplets found to be smaller than a certain droplet size. Also the slope of the CDF curve indicates
droplet size distribution. If the slope of the is high that means the percentage of smaller droplets is higher and vice
versa.

CDF is also very effective in comparing 1D and 2D PDA results.

Diameter PDF Profiles with Rosin Ramler Fits at Z=-
5mm (t=2-2.5ms)
Peak at 6 microns Peak at 4 microns

Peak at 4 microns

R=-6mm
R=-4mm Centre of the Plume R=-8.5mm

Again PDF plots confirm the fact that bigger droplets are found in the centre of plume.

In order to make these profiles usable, a function needs to be defined which can readily provide the distribution function at any location. For this

Purpose Rosin Ramler distribution Function is used.

Rosin Ramler Profiles can be used as the boundary condition in a simulation. The profile close to the injector is very important because it can be a

measure of primary atomization.

Rosin Ramler distribution Function is presented in next slide.

Droplet Velocity Distribution Function
Velocity distribution follows normal distribution which is also known as
Gaussian Distribution function

 1 2
PDF → Fpdf =
1
exp − (V − Vm) 
2
2
Sn  2S n 
 S =  (Vi − Vm)
21 N 2
n
N i=1

where, V is the droplet velocity, Vm is the mean droplet

velocity.
Sn is the spread factor.
Velocity PDF Profiles with Gaussian Distribution Fits
at Z=-5mm (t=2-2.5ms)

R=-6mm R=-8.5 mm
R=-4mm
Centre of Plume

Gaussian distribution gives a good estimate of the velocity spread in the spray.
Centre of the plume has a very high velocity with a thin spread.
In the Periphery the velocity spread is very large. This means some fast moving big droplets
are pushed to the periphery.
A small amount of negative velocity is observed in the periphery of the plume because of high
shear.
Joint PDF (JPDF) Plot at Different Radial positons at (Z=-
5mm for t=2-2.5 ms)
Diameter indicator

R=-6 R=-8.5
R=-4
Plume Centre

Velocity indicator

Joint PDF defines the probability in terms of both diameter and velocity of droplets.

At the periphery, the JPDFs show that the droplets are mainly concentrated to 3.5 microns with velocity 15 to 25 m/s.

and 5.5 microns with velocity of 90m/s at the centre of Plume.

High velocity at the centre of the plume is the result of high percentage of momentum carried by the bigger droplets.

A very large difference in the velocity for the similar sized droplets is seen. This shows the bigger droplets are

breaking up in to smaller ones.

4. Comparison between 1D and 2D PDA
Measurements
1D PDA vs 2D PDA (Near Nozzle Measurements) at Z=-5mm & R=-6mm (t=2-2.5ms)

1D PDA 2D PDA

1D PDA tends to measure higher number of smaller droplets than

2D due to better droplet acceptance percentage. Much steeper

CDF curve of 1D data confirms this fact.

This difference is mainly due to higher rejection rate of 2D PDA.

Droplet acceptance ratio of 1D measurements is slightly higher in

near nozzle cases but at 10 mm the difference is negligible.

Accepted samples
acceptance% = *100
Attempted Samples
CDF Analysis of 1D PDA vs 2D PDA Near Nozzle Measurements
CDF percentage (%) Diameter 1D PDA Diametr 2D PDA
99 %
95 % 50 4.21 5.85
75 %
50 % 75 6 8.2
95 8.8 12.25
99 10.95 15.05
1D PDA
Comparison of 1D and 2D PDA data at plume
Centre

16 (1D PDA)
2D PDA 14 (2D PDA)
12

(microns)
Diameter
99 % 10
95 %
75 % 8
50 % 6
4
2
0
40 45 50 55 60 65 70 75 80 85 90 95 100
CDF percentage (% )

A significant difference in the measurements of the 1D and 2D PDA techniques is observed by looking at CDF percentage.

50% of the droplets are less than 4.21 microns in 1D and 5.85 microns in 2D PDA.

5% of the droplets are bigger than 8.8 and 12.25 microns in 1D in 2D cases respectively. And its very important to get rid of these big droplets.

The acceptance ratio in 1D PDA and 2D PDA is very low in near injection measurements that means big ligaments and blobs have not been captured.
2D PDA Data Analysis (Downstream) (Different
Experiment)
PDF comparison of Diameter at z= 20, -37,5, -55 mm
axial distance for t=3-3,2 ms. Accptance Ratio of PDA 2D at different
Radial positions
80
0.15 70

acceptance (%)
60

Percentage of
Probability

0.1 50

40
0.05 z=-55 30
Z=-37,5 20
0
0

z=-20 10
4
8
12
16
20
24
28
32

0
36
40
44
15 25 35 45 55 65
Droplet Diameter (micron)
Axial Downstream Positions (mm)

PDF of Diameter Droplet Acceptance Percentage

The spray breaks down considerably at 55mm downstream position, as shown in the PDFs of droplet
diameter.

This plot is shown from a. Acceptance ratio increases linearly with the increase in break up.

The droplet acceptance ratio is around 75% at 60 mm. This means there are still some blobs present in the
spray which may have failed to brake down until this far. This may be linked to the injector closure and
needle bounce.
Conclusion
In the raw data analysis a few number of blobs (70-100 microns) have been
observed in the early part of injection. These blobs disintegrate to smaller
droplets after 7.5mm distance. These blob are so big that only one blob changes
the values of SMD and D90 completely.
Needle bounce effect produces big droplets which penetrate far in to the spray.
Mostly, 50 % of the droplets Captured are less than 5 microns and 78% are less
than 10 microns at Z=-5 mm (axial position) for 2D case.
Droplets bigger than 10 microns have highest momentum & kinetic Energy. But
due to the low number of bigger droplets captured, results are biased towards
smaller droplets.
Droplet acceptance Ratio for 1D and 2D PDA are is relatively very low. So one
should be very careful before using these results. This needs to be addressed in
order to find out the effect of atomization.
Away from the nozzle the droplet acceptance ratio increases considerably.

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