A STUDY OF THE SPRAY CHARACTERISTIC FOR VALVE COVERED ORIFICE DIESEL NOZZLE INJECTOR

USING CFD

AHMAD AIZUDDIN FAIZ BIN CHE JAAFAR

UNIVERSITI MALAYSIA PAHANG

UNIVERSITI MALAYSIA PAHANG

BORANG PENGESAHAN STATUS TESIS

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24, LORONG PASIR PUTEH, Dr. ABDUL ADAM BIN ABDULLAH

PASIR PANJANG, ( Nama Penyelia )

21100 KUALA TERENGGANU.

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Tarikh: 27 JUNE 2013 Tarikh: : 27 JUNE 2013

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Penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan

penyelidikan, atau Laporan Projek Sarjana Muda (PSM).

2012/2013

AHMAD AIZUDDIN FAIZ BIN CHE JAAFAR (850113-11-5295)

A STUDY OF THE SPRAY CHARACTERISTIC FOR VALVE

COVERED ORIFICE DIESEL NOZZLE INJECTOR USING CFD

A STUDY OF THE SPRAY CHARACTERISTIC FOR VALVE COVERED ORIFICE

DIESEL NOZZLE INJECTOR USING CFD

AHMAD AIZUDDIN FAIZ BIN CHE JAAFAR

Thesis submitted in fulfillment of the requirements

for the award of the degree of

Bachelor of Mechanical Engineering with Automotive Engineering

Faculty of Mechanical Engineering

UNIVERSITI MALAYSIA PAHANG

JUNE 2013

ii

EXAMINERS APPROVAL DOCUMENT

UNIVERSITI MALAYSIA PAHANG

FACULTY OF MECHANICAL ENGINEERING

I certify that the report entitled ‘A Study of The Spray Characteristic for Valve Covered

Orifice Diesel Nozzle Injector using CFD’ is written by Ahmad Aizuddin Faiz Bin Che

Jaafar. I have examined the final copy of this report and in my opinion, it is fully

adequate in terms of language standard, and report formatting requirement for the award

of the degree of Bachelor of Mechanical Engineering with Automotive Engineering. I

herewith recommend that it be accepted in fulfillment of the requirements for the degree

of Bachelor of Engineering.

Signature:

Name of Examiner: MR WAN ANUAR WAN HASSAN.

Date:

iii

SUPERVISOR’S DECLARATION

I hereby declare I have checked this report, which written by Ahmad Aizuddin Faiz Bin

Che Jaafar, and in my opinion, this report project is adequate in terms of scopes and

quality for the award of the degree of Bachelor of Mechanical Engineering with

Automotive Engineering.

Signature:

Name of Supervisor: DR. ABDUL ADAM BIN ABDULLAH

Position: LECTURER

Date:

iv

STUDENT’S DECLARATION

I hereby declare that the work in this report is my own, except for quotations and

summaries which have been duly acknowledged. The report has not been accepted for

any other degree and is not concurrently submitted for award of other degree.

Signature:

Name: AHMAD AIZUDDIN FAIZ BIN CHE JAAFAR

ID Number: MH08083

Date:

viii

TABLE OF CONTENTS

Page

EXAMINERS APPROVAL DOCUMENT ii

SUPERVISOR’S DECLARATION iii

STUDENT’S DECLARATION iv

ACKNOWLEDGEMENTS v

ABSTRACT vi

ABSTRAK vii

TABLE OF CONTENTS viii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF SYMBOLS xiv

LIST OF ABBREVIATIONS xv

CHAPTER 1 INTRODUCTION

1.1 Introduction 1

1.2 Problem Statement 3

1.3 Objectives 3

1.4 Scope 4

1.5 Methodology 4

CHAPTER 2 LITRATURE REVIEW

2.1 Introduction 5

2.2 Diesel Engine 5

2.3 Viscosity 6

2.3.1 Diesel Fuel 7

2.4 Spray Combustion Process 7

2.5 Spray Regime 9

2.6 Spray Penetration 10

2.7 Nozzle Parameters 13

ix

2.7.1 Valve Covered Orifice Nozzle Injector 13

2.8 Computational Fluid Dynamics (CFD) 15

CHAPTER 3 METHODOLOGY

3.1 General Methodology 16

3.2 Literature Study 16

3.3 Flow Chart/ Project Flow 18

3.4 3D Design Modeling 19

3.5 ANSYS Fluent Simulation Setup 21

3.5.1 Geometry 21

3.5.2 Computational Meshing 22

3.5.3 Simulation Setup 23

3.5.4 Graphics and Animations 33

3.6 Measurement Method 34

CHAPTER 4 RESULT AND DISCUSSION

4.1 Introduction 36

4.2 Spray Image 36

4.3 Various Temperature and Pressure 37

4.3.1 Temperature at 273 K 37

4.3.2 Temperature at 300 K 39

4.3.3 Temperature at 500 K 40

4.3.4 Temperature at 1000 K 42

4.4 Various Diameter Nozzle Hole Size 46

4.5 Double Hole Nozzle Injector 50

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Conclusion 52

5.2 Recommendations 53

REFERENCES 54

x

APPENDICES 56

A Spray Penetration Length for Various Injection Pressure

And Ambient Temperature 56

B Spray Cone Angle for Various Injection Pressure

And Ambient Temperature 56

C Spray Penetration Length and Spray Cone Angle for

Various Nozzle Diameter 56

D Gantt Chart / Project Schedule for FYP 1 57

E Gantt Chart / Project Schedule for FYP 2 58

xi

LIST OF TABLES

Table No. Page

2.1 Comparison of Viscosity among Diesel, Biodiesel and

Vegetable Oils 6

2.2 Hydrocarbon Contents in Crude Oil 7

2.3 Summary of Diesel Spray Characteristic 10

2.4 Parameter of the Nozzle and Injection Strategy 15

xii

LIST OF FIGURES

Figure No. Page

2.1 The Consecutive phase’s during the operation of a

Diesel engine 8

2.2 The Basic Type of Single-Hole Injector Nozzle 14

3.1 Flow Chart 18

3.2 3D Design of Combustion Chamber 19

3.3 Closed Chamber Volume with the Nozzle injector Hole

In Isometric View 20

3.4 Closed Chamber with Nozzle Injection Volume

Dimension 20

3.5 ANSYS Fluent Software Layout 21

3.6 Named Selection Surface Processes in Geometry 22

3.7 The Meshing Process with the higher Refinement Level 23

3.8 General Setup Option button 23

3.9 Reorder Step 24

3.10 The Report of the Reorder Progress 24

3.11 The setting in the Model Setup 25

3.12 Viscous Model Setting 25

3.13 Species Model Setting 26

3.14 Discrete Phase Model Panel, Physical Model Tab

Setting 27

3.15 Discrete Phase Model Panel, Tracking Tab setting 28

3.16 Pressure Inlet Panel setting 29

3.17 Pressure Outlet Panel setting 30

3.18 Operating Condition Panel setting 31

xiii

3.19 The Solution Method setup 31

3.20 Solution Initialization Panel setup 32

3.21 The Simulation Process by 350 Iteration 33

3.22 The Contour Panel setting 34

3.23 The Measurement Scale 35

4.1 Spray Image Contour Line Type 37

4.2 The Spray Contour of 273 K 38

4.3 The Spray Contour of 300 K 40

4.4 The Spray Contour of 500 K 41

4.5 The Spray Contour of 1000 K 43

4.6 Spray Penetration Length vs Ambient Temperature

Graph (0.2mm) 44

4.7 The Spray Cone Angle vs Ambient Temperature

Graph (0.2mm) 45

4.8 Spray Characteristic of the Various Nozzle Diameters

Hole 48

4.9 Spray Penetration Length vs Nozzle Diameter 49

4.10 Spray Cone Angle vs Nozzle Diameter 49

4.11 The Spray Pattern for Multi-Hole of Nozzle 51

4.12 The Simulation Spray Pattern for Double Hole of

Nozzle 51

xiv

LIST OF SYMBOLS

Nitrogen Oxide

O Water

B20 2-% of Biodiesel

KPa KiloPascal

MPa MegaPascal

K Kelvin

Mm Milimeter

% Percentage

ᵒ Degree

θ Teta

L Length

VS Versus

xv

LIST OF ABBREVIATIONS

VCO Valve Covered Orifice

CFD Computational Fluid Dynamics

HSDI High Speed Direct Ignition

3D 3 Dimension

cc Centimeter Cubic

hp Horse Power

rpm Revolution per Minute

PLN Pump Line Nozzle

Injection Pressure

Ambient Pressure

Atmosphere Pressure

Ambient Temperature