bluuebunny/crossref_metadata_2025 huggingface dataset:
Austempered Ductile Iron, Green Design Alternative for Circular Economy
Authors: Nalawade Dinkar , Arcot Pramaan , Khajure Rahul
Published: November 2023

In the current scenario, manufacturing of heavier products generates colossal waste, generates more CO2 emission, and negatively affects the environment. Customers not only pay higher product costs but also higher operational costs. This in turn demands the need for more recycling. Advanced high strength materials are a key solution to applications demanding higher strength, stiffness, durability & wear requirement, whereas low density materials like aluminium and magnesium won’t be a sustainable choice. With more and more battery electric & fuel cell vehicles, “light weighting” is a key priority.

Austempered Ductile Iron (ADI) has a great advantage of superior mechanical properties compared to conventional ductile iron, aluminium alloys and even some steel forgings. Typically, ADI is used for high wear applications, whereas this paper will demonstrate the potential of using ADI for Structural applications.

To display ADI’s potential on “light weight design”, an example of ‘Front Spring Anchorage’ is selected as a proof-of-concept. Analysis is carried out using Finite Element Method (FEM) on a redesigned component to validate its impact. Up to 40% reduction in weight is achieved on the component which greatly benefits commercial vehicles in terms of energy efficiency & cost. Overall, the paper will also exhibit ADI material’s contribution to concept of “sustainable design”, “circular economy” for a greener future.
Parallel Scheduling of Machines and Tools without Tool Delay Using Symbiotic Organisms Search Algorithm
Authors: Mareddy Padma Lalitha , Reddy D Vishnu Vardhan , Katta Lakshmi Narasimhamu , Siva Rami Reddy Narapureddy
Published: November 2023

This work presents a novel approach for parallel scheduling of machines and tools without tool delay in the automobile manufacturing industry using a symbiotic organisms search algorithm (SOSA). This paper proposes nonlinear mixed integer programming (MIP) formulation to model simultaneous scheduling problems. The mutualistic relationship between different species in nature inspires the proposed algorithm. It aims to optimize the scheduling process by minimizing the makespan (MSN) while ensuring no tool delay during the production process. The algorithm is implemented in a parallel computing environment to speed up the search process and handle scheduling problems. Experimental results show that the proposed approach outperforms existing methods in terms of solution quality and computational efficiency. This work offers a promising solution for real-world manufacturing scheduling problems with multiple machines and tools, often characterized by complex constraints and uncertainties.
Application of Taguchi Based ANFIS Approach in Wire Electrical Discharge Machining of Inconel 625 for Automobile Applications
Authors: Pasupuleti Thejasree , Natarajan Manikandan , Shanmugam Loganayagan , Kiruthika Jothi , Ramesh Naik Mude , Kotapati Gowthami
Published: November 2023

Nickel-based superalloys are most commonly engaged in a numerous engineering use, including the making of food processing equipment, aerospace components, and chemical processing equipment. These materials are often regarded as difficult-to-machine materials in conventional machining approach due to their higher strength and thermal conductivity. Various methods for more effective machining of hard materials such as nickel-based superalloys have been developed. Wire electrical discharge machining is one of them. In this paper, an effect has been taken to develop an adaptive neuro-fuzzy inference system for predicting WEDM performance in the future. To analyse the model’s variable input, the paper employs the Taguchi’s design and analysis techniques. The evolved ANFIS model aims to simulate the process’s various characteristics and predicted values. A comparison of the two was then made, and it was discovered that the predicted values are much closer to the actual outcomes. The investigation’s findings support the manufacturer’s decision-making process and demonstrate the process’s evolved capability.
Application of Taguchi Approach on Wire Electrical Discharge Machining of SS304 for Automotive Applications
Authors: Natarajan Manikandan , Pasupuleti Thejasree , Katta Lakshmi Narasimhamu , Somsole Lakshmi Narayana , D Palanisamy , Kiruthika Jothi
Published: November 2023

SS304 is a type of stainless steel that is well-known for its high ductility and resistance to corrosion; as a result, it is typically utilized in a variety of applications, such as the exhaust systems of automobiles and the springs that are used in seatbelts. Because of its qualities, it will eventually be employed in a variety of body parts, including fuel tanks and chassis, among other things. Due to its properties, SS304 is known to be incredibly difficult to machine using conventional methods. Through a wire electrical discharge machining process, it is easier to cut complex materials with high surface finishes. In this study, a study was conducted on the WEDM process parameters of SS304 to optimize its machining process. The study was carried out using the DoE approach, which involved planning the various experiments. The parameters of the process, such as the pulse on time, peak current, and off time, were analyzed to determine their performance. The various performance measures included surface roughness, overcut, and removal rate. The results of the study were then analyzed with an interaction plot analysis. The influence of the various process variables on the output measures were then studied through this analysis.
Investigations on Wire Electrical Discharge Machining of Magnesium Alloy for Automobile Parts
Authors: Natarajan Manikandan , Pasupuleti Thejasree , D Palanisamy , Kumar V , Kiruthika Jothi , Polanki Vamsinath
Published: November 2023

Magnesium alloy, known for its high strength and lightweight properties, finds widespread utilization in various technical applications. Aerospace applications, such as fuselages and steering columns, are well-suited for their utilization. These materials are frequently employed in automotive components, such as steering wheels and fuel tank lids, due to their notable corrosion resistance. The performance of magnesium alloy components remains unimproved by normal manufacturing methods due to the inherent characteristics of the material. This work introduces a contemporary approach to fabricating complex geometries through the utilization of Wire-Electro Discharge Machining (WEDM). The material utilized in this study was magnesium alloy. The investigation also considered the input parameters associated with the Wire Electrical Discharge Machining (WEDM) process, specifically the pulse duration and peak current. The findings of the study encompassed the material removal rate and surface roughness. Taguchi successfully employed a single aspect optimization technique to ascertain the ideal combination that would enhance the efficacy of the WEDM process. The findings of the investigation revealed that the proposed technique significantly improved the efficiency of the WEDM approach.
Design, Modelling and Simulation of Adaptable Marine and Terrestrial Cleaner
Authors: Kumar V Sudhir , R Balamurugan , Pasupuleti Thejasree , Natarajan Manikandan
Published: November 2023

An oil spill refers to the accidental or deliberate release of petroleum or other petroleum-based products into the environment. These spills can occur on land or in water bodies, such as oceans, rivers, or lakes, and can have devastating impacts on the environment, wildlife, and human health. Oil spills can harm aquatic and terrestrial ecosystems by contaminating water and soil, and by affecting the food chain. They can also cause economic losses, such as the loss of fisheries, tourism, and property values. Cleaning up oil spills can be a difficult and expensive process, and the effectiveness of the response can depend on various factors, such as the type and amount of oil spilled, weather conditions, and proximity to sensitive ecosystems. Preventing oil spills is critical to minimizing their impacts. This can be achieved through measures such as regular maintenance of oil transport and storage facilities, the use of double- hulled tankers, and the implementation of emergency response plans.

Additionally, reducing our dependence on fossil fuels and transitioning to cleaner sources of energy can help to decrease the risks of oil spills. We have given an ideal proposal to clear the oil spills in the marine region and in the seashore to avoid massive pollution in the ecosystem and to provide a clean environment. In our idea proposal, we have planned to combine the road cleaning system with the oil spill cleaning system, so that it can be used for dual purposes and to clean in an efficient manner. This proposed invention aims to combine the functions of both oil skimmers and road sweeper machines into a single machine. The machine will be capable of removing oil spills from water surfaces as well as collecting debris and dust from roads and other surfaces. The design will utilize existing technologies and adapt them for this combined purpose, resulting in a more efficient and cost-effective solution for environmental clean-up and maintenance. This work highlights the potential benefits of this innovation, including increased productivity and reduced environmental impact.
Application of Taguchi Based ANFIS Approach in Wire Electrical Discharge Machining of Haste Alloy C276 for Automobile Applications
Authors: Pasupuleti Thejasree , Natarajan Manikandan , R Balamurugan , Krishnamachary PC , Katta Lakshmi Narasimhamu , Kiruthika Jothi
Published: November 2023

Superalloys, also known as nickel alloys, are widely employed in a wide variety of engineering applications, including the creation of parts for the chemical processing industry and appliances for the food processing industry. Their high heat conductivity and strength, among other characteristics, make them challenging to machine using traditional techniques. Instead, cutting-edge techniques are typically created for the milling of such tougher materials. In this study, we use a modern method called wire electrical discharge machining, which is typically used for working with tougher materials. In order to anticipate WEDM variables, this paper aims to create a Grey-based Artificial Neural Network (ANN) Model and Adaptive Neuro Fuzzy Inference System. The paper uses a Taguchi method to investigate the model’s varying inputs. The purpose of this model is to visualize the process’s varying performance characteristics. The model’s projected values have been compared to the experimental data, and it has been shown that the two sets of numbers are quite closely related. Developed model’s capabilities have been validated through rigorous testing, allowing the maker to make informed judgments.
Mechanical Control Cable Modeling and Simulation to Predict the Load Loss and Deformation
Authors: Subbaiyan Prasanna Balaji , Nizampatnam Balaramakrishna , Redkar Dinesh , Sathusundarsingh Anand , Muniappan Balakrishnan
Published: November 2023

Mechanical control cables or Bowden cables are widely used in various applications for push-pull actions of mechanical systems. In mid-segment tractors, the linkage systems are designed along with control cables to actuate controls such as throttle, braking, transmission shift, position control, etc. due to its design flexibility. Output force and travel efficiency are two major performance parameters that depend on the routing, cable design composition, friction material, load transfer, etc. Virtual simulations can be used to predict cable performance and efficiency. There are different methodologies currently used to model the cable. These available methods can accurately predict either performance or travel efficiency. There is no method available in-house to predict both these parameters.

In this paper, a new cable modeling method is proposed by authors using multi-body simulation (MBS) software MSC ADAMS. Outer composite cable sheath and translating wire are modeled using flex-body model neutral file (*mnf) generated from Finite Element Analysis (FEA) software ABAQUS. These flex-bodies are uniquely connected to represent the entire cable. This modeling method is used for predicting cable performance.

To validate this method, the U-Bend test and tractor-level tests are performed to study cable force and travel on input and output ends. The correlation between measured and virtual simulation results is above 85%. This method can be used to model and analyze cable efficiency and performance.
Investigation on Hybrid Cooling Topologies of Li-Ion Battery Pack for Electric Vehicles
Authors: Selvan V. Arul Mozhi , S Palanisamy , Bharadwaj Hari
Published: November 2023

The performance standards of Li-ion batteries used in EVs have skyrocketed, owing to their rapid commercialization in recent years. This has made Li-ion battery thermal management more vital than ever before, as optimum performance is achieved only when the batteries are within the narrow temperature range of 25° to 40°C. However, the operating temperatures in a lot of EVs go way beyond 40°C, leading to a reduction in the battery performance and lifetime. This study aims to solve this problem by improving the battery packing and maintaining the battery temperature via a hybrid cooling system which involves both air-cooling and liquid cooling. The aim is achieved by varying the liquid coolant used in the system and the cell arrangement in the battery module which has 32 cells in an 8x4 arrangement. Water-ethylene glycol solution and two other nanofluids, namely cu-nanofluid (1% vol) and CNT-nanofluid (0.1% vol) have been used as the coolants while the cell arrangements considered are the aligned, staggered and cross arrangements. In the numerical model of the 6Ah, 123 V battery pack, each battery cell generates about 5 W and is represented as a cylinder enclosed in a case with an air-cooling setup and two liquid cool plates on the top and bottom being directly in contact with the battery cells. The model is simulated using ANSYS Fluent for various cell arrangements and coolants to identify the temperature profile of the entire battery. The best cooling effect was achieved with the staggered configuration, with the liquid coolant being Cu-nanofluid (1%). In this case, the maximum battery temperature was limited to 35.078°C.
Capturing Combustion Chemistry of Carbon-Neutral Transportation Fuels
with a Library of Model Fuels
Authors: Puduppakkam Karthik V. , Meeks Ellen
Published: November 2023

Carbon-neutral (CN) fuels will be part of the solution to reducing global warming
effects of the transportation sector, along with electrification. CN fuels such
as hydrogen, ammonia, biofuels, and e-fuels can play a primary role in some
segments (aviation, shipping, heavy-duty road vehicles) and a secondary role in
others (light-duty road vehicles). The composition and properties of these fuels
vary substantially from existing fossil fuels. Fuel effects on performance and
emissions are complex, especially when these fuels are blended with fossil
fuels.

Predictively modeling the combustion of these fuels in engine and combustor CFD
simulations requires accurate representation of the fuel blends. We discuss a
methodology for matching the targeted fuel properties of specific CN fuels,
using a blend of surrogate fuel components, to form a fuel model that can
accurately capture fuel effects in an engine simulation. Fuel components are
drawn from a database of surrogates, the Ansys Model Fuel Library (MFL) [1], for this purpose. The database has 73
surrogate components, including n-alkane,
iso-alkane, naphthene, aromatic, alkene,
iso-alkene, alcohol, ether, cyclic ether, methyl ester, ketone
and acid chemical classes, in addition to hydrogen, CO and ammonia. This wide
range of components makes it possible to assemble fuel models for hydrogen,
ammonia, biofuels, e-fuels, existing fossil-fuels, and any blends thereof. The
database of surrogate components includes kinetics derived from self-consistent
rate rules that capture combustion behavior, including autoignition, flame
propagation and emissions of soot, NOx, CO and unburned hydrocarbons (UHC). We
include details of representative validation studies for the kinetics of
individual components and some blends, comparing to fundamental experiments.
Accompanying software tools for targeted mechanism reduction make the chemistry
applicable for engineering CFD simulations. The accurate representation of fuel
properties and kinetics of CN fuels from this database facilitates predictive
engine simulations, toward the optimization of both fuels and engines.
Adapting Dimensionless Numbers Developed for Knock Prediction Under Homogeneous Conditions to Ultra-Lean Spark Ignition Conditions
Authors: Strickland Tyler , Lopez-Pintor Dario , Matsubara Naoyoshi , Kaneko Kazuki , Kitano Koji
Published: November 2023

Knock in spark-ignition (SI) engines has been a subject of many research efforts and its relationship with high efficiency operating conditions keeps it a contemporary issue as engine technologies push classical limits. Despite this long history of research, literature is lacking coherent and generalized descriptions of how knock is affected by changes in the full cylinder temperature field, residence time (engine speed), and air/fuel ratio. In this work, two dimensionless numbers are applied to fully 3D SI conditions. First, the characteristic time of autoignition (ignition delay) is compared against the characteristic time of end-gas deflagration, which was used to predict knocking propensity. Second, the temperature gradient of the end-gas is compared against a critical detonation-based temperature gradient, which predicts the knock intensity. These dimensionless numbers’ relationship to knocking propensity and intensity of specific cylinder conditions is investigated via 3D computational fluid dynamics (CFD) simulations utilizing a large eddy simulation (LES) framework. Simulations of a light-duty SI engine fueled with a gasoline surrogate are performed at various engine speeds (1400 rpm and 2000 rpm) and air/fuel ratios (λ =1 and 2), and end-gas temperature stratifications. The dimensionless numbers’ ability to predict knocking propensity and intensity magnitudes while being invariant to other phenomenon across these various operating conditions is validated.
Development of film heat transfer model based on multiphase flow numerical analysis
Authors: Nagasawa Takeshi , Uchida Kenji , Yamashita Hiroyuki
Published: November 2023

Automobiles will have to be applied strict regulations such as Euro7 against PM, HC, CO. The generation of these components are related to fuel deposition to the wall surface of the combustion chamber. Therefore, the fuel injection model of engine combustion CFD requires accurate prediction about the deposition and vaporization of fuel on the combustion chamber. In this study, multiphase flow numerical analysis that simulates fuel behavior on the wall surface was conducted first. Then, two model formulae about the contact area and the heat flux of a liquid film was constructed based on the result of multiphase flow numerical analysis method. Finally, the new film heat transfer model was constructed from these model formulae. In addition, it was confirmed that new heat transfer model can predict the liquid film temperature obtained by multiphase flow numerical analysis method accurately.
A Study of Autoignition and Combustion Characteristics in an HCCI Engine using a Blended Fuel of DME and City Gas
Authors: Yamagiwa Reo , MANABE Yusuke , MITO Shinji , IIJIMA Akira , YOSHIHARA Shintaro , YAMAGUCHI Takahiro , MIYAMOTO Sekai
Published: November 2023

In recent years, there has been a need to reduce CO2 emissions from internal combustion engines in order to achieve an energy-saving and low-carbon society. Against this backdrop, the authors have focused attention on Homogeneous Charge Compression Ignition (HCCI) combustion that achieves both high efficiency and clean emissions. With HCCI combustion, a premixed mixture of fuel and air is supplied to the cylinder and autoignited by piston compression to drive the engine. Autoignition makes it possible to operate the engine at a high compression ratio, enabling the HCCI combustion system to attain high efficiency. However, HCCI combustion also has some major unresolved issues. Two principal issues that can be cited are ignition timing control for igniting the mixture at the proper time and assurance of suitable combustion conditions following ignition to prevent incomplete combustion and knocking. The combustion characteristics of a blended fuel of dimethyl ether (DME) as the ignition source and city gas as the main fuel, which have vastly different ignition characteristics, were investigated in experiments conducted with a test engine. The intermediate combustion products of the two fuel components were also investigated and analyzed by conducting chemical kinetic simulations. The results revealed that, combustion of a mixture of DME and city gas was strongly affected by methane, which was the main component of the mixture and slowed down the main combustion, while other alkanes showed a slowing effect on low-temperature oxidation reactions.
Investigation of Dimethyl Ether Dual-Fuel Combustion Using Propane and Ethanol as Premixed Fuel
Authors: LeBlanc Simon , Wang Linyan , Yu Xiao , Zheng Ming
Published: November 2023

The combustion and emission characteristics of dual-fuel combustion were investigated using dimethyl ether direct injection and premixed low-carbon fuels. Dimethyl ether was used as the direct injection fuel for its high reactivity and low propensity to form particulate matter. Ethanol and Propane, two fuels of low reactivity, were premixed in the intake port. An injection timing sweep of varying premixed energy shares and engine loads was tested. Combustion analysis was conducted based on in-cylinder pressure measurements while detailed speciation of engine-out emissions was performed via FTIR. The proper injection advance and premixed energy share can realize low NOx and high combustion efficiency. Ethanol showed stronger impact to DME ignition delay as compared with propane.
Instability of emery oil particle for 10 nm engine exhaust CPC calibration
Authors: Kojima Kentaro , Murashima Yoshiko , Sakurai Hiromu , Otsuki Yoshinori , Kondo Kenji
Published: November 2023

This research examined CPC calibration error due to the instability of 10 nm particle. Tandem DMA set-up was used to measure the actual particle size. Emery oil particle shrinks by 0.3 nm after classifier. Residence time in the downstream also affects the shrinkage with its rate 0.18 nm per second. In addition, we confirmed 7 nm particle shrinks more, as anticipated on Kelvin equation. Due to this shrinkage, CPC detection efficiency of 10 nm was reduced by 3% approximately.
Development of Oil Behavior Visualization Technology using X-Ray Computed Tomography
Authors: Tanaka Daisuke , Fujieda Hiroki , Ute Junji , Uchida Mitsunobu , Matsuo Takeo , Tanase Masataka , Hiura Yuki
Published: November 2023

Recently, it has become possible to dynamically observe the internal oil behavior using a medical X-ray computed tomography (CT) system, which can capture internal images without disassembling the object being evaluated. The problem in applying the CT method to lubrication analysis is the artifact, like noise, which occurs during dynamic observation. In this paper, we developed a method to reduce this artifact with machine learning by generating artifacts through simulation and using them as supervised data.
An Investigation of Oil Supply Mechanisms to the Top of the Liner in Internal Combustion Engines
Authors: Li Mo , Zhong Xinlin , Ahling Sebastian , Tian Tian
Published: November 2023

Protecting the piston ring and liner interface is critical to the proper operation of internal combustion engines. Specifically, the dry region, which is the portion of the liner above the Top Dead Center (TDC) of the Oil Control Ring (OCR), needs proper lubrication to reduce wear and to maintain sustainability. However, the mechanisms by which oil is distributed to such region have not been investigated. This paper presents the first attempt to understand dry region lubrication by means of the oil-gas interaction below the top ring gap through a combination of experimental and modeling approaches.

An optical engine with 2D Laser Induced Fluorescence (2D-LIF) technique was applied to visualize the oil flow below the top ring gap. It was observed that the two vortices downstream the top ring gap can cause oil bridging towards the liner, providing lubrication to the ring-liner interface. On the modeling side, a 3D machine learning model was developed to predict the vortex flow pattern for different pressure boundary conditions. It was found that the size and the strength of the vortex grows with increasing ratio of the upstream and downstream pressure. The combination of modeling and experimental results identified that oil bridged towards the liner by vortex is the major contributing factor to dry region lubrication.
A Study on Developing MPI Hydrogen ICE over 2MPa BMEP for Medium Duty Vehicles
Authors: Hiyama Daisuke , Ito Akemi , Nishibe Koichi , Nozaki Satoru , Nanba Yoshinori , Yamaura Takuya , Takeda Keiso , Sasaki Ryuichi , Naganuma Kaname
Published: November 2023

Hydrogen ICE can achieve carbon neutrality and is adaptable to medium and heavy-duty vehicles, for which electricity is not always a viable option. It can also be developed using high-quality conventional diesel/gasoline engine technology. Furthermore, it allows for the conversion of existing engines to hydrogen ICE, making it highly marketable. The reliability and durability of MPI hydrogen ICE is better than that of DI, and MPI has an advantage over DI in terms of cruising range because the low-pressure injection of hydrogen reduces the remaining hydrogen in the tank. Improving MPI output is, however, an important subject, and achieving this requires suppressing abnormal combustion such as pre-ignition. In this study, an inline four-cylinder 5L turbo-charged diesel engine was converted to a hydrogen engine. Hydrogen injectors were installed in the intake ports and spark plugs were installed instead of diesel fuel injectors. A two-stage turbo system was adopted to improve the engine output as turbocharging is required for MPI hydrogen engines in a wide range of engine speeds. The effect of piston combustion chamber shape, compression ratio, valve timing, and injection timing were optimized. As a result, the engine achieved 2MPa BMEP and 103% of the low-speed torque of the base diesel engine. Finally, the medium-duty truck using the newly developed hydrogen ICE was also presented in this paper.
Analysis of the effect of hydrogen combustion characteristics on engine performance
Authors: Tsukamoto Yoshihisa , Tanno Shiro , Miyamoto Yoshinori , Sakai Hiroyuki , Omura Tetsuo , Takahashi Daishi
Published: November 2023

The use of hydrogen produced from renewable energy sources is expected to be one of the most promising options for achieving carbon neutrality in automobiles, in addition to electrification and the use of biofuels and synthetic fuels. In recent years, along with fuel cell electric vehicles (FCEVs), there has been renewed interest in hydrogen engines that can utilize internal combustion engine technology. Although hydrogen has the property of a high laminar burning velocity and a wide flammable range compared to other fuels, the actual combustion phenomenon in a real engine is strongly influenced by the turbulence created by the in- cylinder flow and the distribution of fuel and air in the cylinder due to the formation of the mixture. Therefore, to fully utilize hydrogen as a fuel in actual engines and bring out its performance, it is important to understand the basic combustion characteristics of hydrogen in the cylinder and the effects of these factors on hydrogen combustion. In this paper, we analyzed the basic combustion characteristics of hydrogen using actual engines under conditions that consider its use in automobiles and investigated the effect of turbulence on hydrogen combustion characteristics in the cylinder. Based on these results, we discuss improvements to the potential of hydrogen engines.
Numerical simulation of effects of operating parameters on combustion in a hydrogen direct injection engine
Authors: Zhen Fu , Wenzhi Gao , Duanzheng Zhao , Yuhuai Li
Published: November 2023

In this study, a three-dimensional numerical model of a hydrogen direct injection engine was built, and the effects of several engine operating parameters, including equivalence ratio, injection timing, ignition timing and intake pressure on combustion were analyzed. The results show that with a fixed ignition timing and intake pressure of 1.0 bar, an increase in the equivalence ratio from 0.3 to 1.1 leads to a reduction in indicated thermal efficiency from 47.3% to 37.73% due to increasing wall heat loss. The NOX emissions first increase and then decrease, arriving the peak at the equivalence ratio of 0.7, about 20.9g/kW·h, primarily attributed to the combined effect of oxygen content, cylinder temperature, and hydrogen reducibility. When the equivalence ratio is fixed at 0.5, with the injection timing delayed, the stratification of the mixture becomes more obvious, the combustion speed accelerates, and the maximum thermal efficiency increases. At the same time, NOX emissions also increase due to local high temperature in the cylinder. Furthermore, at the same equivalence ratio, increasing intake pressure reduces the proportion of wall heat loss, resulting in increased maximum thermal efficiency. Nevertheless, the rise in hydrogen mass increases the MMF2500K within the cylinder, leading to an increase in NOX emissions.
Characterization of Gaseous and Particle Emissions of a Direct Injection Hydrogen Engine at Various Operating Conditions
Authors: Berg Victor , Koopmans Lucien , Sjöblom Jonas , Dahlander Petter
Published: November 2023

This paper investigates the gaseous and particulate emissions of a hydrogen powered direct injection spark ignition engine. Experiments were performed over different engine speeds and loads and with varying air- fuel ratio, start of injection and intake manifold pressure. An IAG FTIR system was used to detect and measure a variety of gaseous emissions, which include standard emissions such as NOX and unburned hydrocarbons as well as some non-standard emissions such as formaldehyde, formic acid, and ammonia. The particle number concentration and size distribution were measured using a DMS 500 fast particle analyzer from Cambustion. Particle composition was investigated using ICP analysis as well as a Sunset OC/EC analyzer to determine the soot content and the presence of any unburned engine oil. The results show that NOX emissions range between 0.1 g/kWh for a λ of 2.5 and 10 g/kWh λ of 1.5. The highest particle concentration was found for low loads and low intake pressures, with peaks values as high as 5*108 n/cc. ICP analysis confirmed that the particles contained traces of engine oil, while the OC/EC analysis showed that 99% of particle matter collected on filters was organic carbon, and <1% soot. The emissions of N2O as well as several other species measured with FTIR was found to be in the single ppm range, and thus not significant.
Clarification of Fuel and Oil Flow Behavior Around the Piston Rings of Internal Combustion Engines
Authors: Mihara Yuji , Hirose Yuya , Oikawa Masakuni , Kyuu Seikou , Nakakouji Haruto , Sanda Shuzo , Azetsu Akihiko , Kawamoto Yuki , Inoue Naoki , Ito Yuto , Ochiai Masayuki , Takahashi Shun
Published: November 2023

The mechanism of lubricant dilution by post injection fuel in a diesel engine was investigated. The operating conditions of the engine were changed, and oil was sampled from each part of the piston and the crankcase, and the dilution ratio was analyzed. Also, photochromism was used to visualize the oil and fuel flow. Dilution ratios obtained from oil sampling and photochromism showed the same tendency.
Thermal efficiency improvement in twin shaped semi- premixed diesel combustion with a combustion chamber dividing fuel sprays and optimization of fuel ignitability
Authors: Inaba Kazuki , Kobashi Yoshimitsu , Shibata Gen , Ogawa Hideyuki
Published: November 2023

The authors have reported significant smoke reduction in twin shaped semi-premixed diesel combustion with a newly designed combustion chamber to distribute the first and the second sprays into upper and lower layers. However, the first stage premixed combustion tends to advance far from the TDC, resulting in lowering of thermal efficiencies. In this report, improvement of thermal efficiency by optimizing the combustion phase with lower ignitability fuels was identified with the divided combustion chamber. The experiment was conducted with four fuels with different cetane numbers. The first stage premixed combustion can be retarded to the optimum phase with the fuel with cetane number 38, establishing high efficiencies.
A Numerical Model for the Virtual Calibration of a Highly Efficient Spark Ignition Engine
Authors: ROLANDO Luciano , MILLO Federico , CASTELLANO Giuseppe , TAHTOUH Toni , ANDRE Mathieu , BOCCHIERI Francesco
Published: November 2023

Nowadays numerical simulations play a major role in the development of future sustainable powertrain thanks to their capability of investigating a wide spectrum of innovative technologies with times and costs significantly lower than a campaign of experimental tests. In such a framework, this paper aims to assess the predictive capabilities of an 1D-CFD engine model developed to support the design and the calibration of the innovative highly efficient spark ignition engine of the PHOENICE (PHev towards zerO EmissioNs & ultimate ICE efficiency) EU H2020 project. As a matter of fact, the availability of a reliable simulation platform is crucial to achieve the project target of 47% peak indicating efficiency, by synergistically exploiting the combination of innovative in-cylinder charge motion, Miller cycle with high compression ratio, lean mixture with cooled Exhaust Gas Recirculation (EGR) and electrified turbocharger. Since the engine is expected to operate in highly diluted conditions, particular attention was paid to the definition of a reliable combustion model to accurately predict the burn duration and the occurrence of abnormal combustion phenomena. A preliminary set of experimental data measured at 3000 RPM and 7 bar BMEP, including both EGR and λ variations, was used to assess the predictive capabilities of the model. Afterwards, the developed virtual test rig was exploited to perform a calibration of the engine in terms of optimal λ and EGR combinations and the results obtained for two operating points, a low load 1500 RPM and 5.5 bar BMEP and a high load 3000 RPM and 13 bar BMEP, were presented and discussed. Findings showed that best efficiency values, well above 40% indicated efficiency, could be obtained with moderate dilution and EGR rates thanks to knock suppression capability for the high load point and de-throttling for the low load point.
Evaluation of swirl ratio effects on the flow fields using Particle Image Velocimetry and Flame image Velocimetry in a small-bore optical compression-ignition engine
Authors: Yang Jinxin , Kim Dongchan , Kook Sanghoon , Kim Kenneth S , Kweon Chol-Bum
Published: November 2023

This study applies high-speed particle image velocimetry (HS-PIV) and flame image velocimetry (HS-FIV) to show flow fields under the effect of varied swirl ratios in a small-bore optical compression-ignition engine. The base swirl ratio and maximum swirl ratio conditions were applied to investigate structures, magnitude and turbulence distribution of the in-cylinder flow as well as the flow within the flame. For each swirl ratio, 100 individual cycles were measured for PIV analysis at motoring conditions and then another 100 cycles for FIV analysis at firing conditions. The derived flow fields were ensemble averaged to show flow structure evolution while the spatial filtering method was applied to extract high-frequency flow component for the analysis of turbulence distributions. The results showed that the intake air flow generates undefined, chaotic flow fields, which are followed by a gradual production of an asymmetric swirl flow. This is due to uneven intake port shape with one spiraling passage and the other straight passage. Upon the formation of a clearly defined swirl flow structure, its centre position rotates in the counter-clockwise direction within the measurement field of view, which impacts the reacting jet flame development with the down-swirl side of the wall-interacting jet penetrating faster. At the maximum swirl ratio realised by blocking the straight port, the intake air flow vectors become more chaotic and stronger, resulting in increased bulk flow magnitude and turbulence. Also, a ring vortex of the flame head on the up-swirl side appears closer to the jet axis while the vectors travelling faster on the down-swirl side than that of the base swirl ratio. Notably, the cyclic variation of in-flame vector magnitude is observed to decrease for the higher swirl ratio, which is attributed to faster mixing to eliminate the high cyclic variation zone formed within the jet-jet interaction region.
Product concept and design process of an SCR Mixer to solve trade-off between urea mixing uniformity and exhaust loss and to improve engineering efficiency
Authors: Ashida Masaaki , Shiga Yoshihiro , Oyanagi Susumu
Published: November 2023

This study presents the development of newly proposed SCR mixer for diesel engine that improves vehicle NOx emission without rebound of the exhaust pressure loss. Unique SCR mixer structure which produces multiple vortices can realize lower NOx emission due to the highly uniform mixing of NH3 generated from the SCR spray and the exhaust gas, compared to the conventional mixer which produce a single vortex. Through its unique mixer structure constructed with some blades that generate multiple vortices. In order to study the mixer structure in a short period of time, 2 steps design process have been studied by separating parametric study in flow analysis and performance confirmation in the dual-phase flow analysis. Consequently, this newly proposed SCR mixer realize excellent mixing performance without increasing the exhaust pressure loss.
Numerical assessment of the performance and emissions of a compact Wankel rotary engine applied as a range extender on the BMW i3 model
Authors: Vorraro Giovanni , Turner James W.G.
Published: November 2023

Amongst all the hybrid-vehicles technologies and layouts, range-extended electric vehicles are the ones with the real prospect to reduce the emissions produced by the thermal machine when in driving conditions, while assuring an adequate range for the common user. The BMW i3 represents one of the most successful series hybrid electric vehicles, having been on the market since 2013. Given the complexities of a hybrid layout employing both thermal and electrical machines, the range extender must have compactness and lightweight characteristics in addition to a suitable power output for the vehicle. Usually, standard 4- stroke small-displacement engines are employed for this application, with the BMW i3 employing a 2- cylinder range extender. More interestingly, a Wankel rotary engine can provide the same amount of mechanical power by reducing the weight and the volume of nearly a third to the equivalent 4-stroke engine. In this study a numerical assessment of the Advanced Innovative Engineering UK (AIE UK) 225CS Wankel rotary engine as a range extender for the BMW i3 was carried out. A full vehicle model of the BMW i3 was built in Siemens Simcenter Amesim 2021.2 to evaluate the behaviour of the aforementioned engine as a range extender. The engine sub-model used was a Mean Value Engine Model (MVEM) set up by implementing the experimental data collected during previous experimental campaign while the BMW i3 chassis sub-model was characterised by using the publicly available data from an Argonne National Laboratory benchmarking project (vehicle weight, front surface, drag coefficient, tires dimensions, etc.). Finally the model was tested over the standard Worldwide harmonized Light vehicles Test Procedure (WLTP) driving cycle in both Charge Depleting and Charge Sustaining modes.
Development of New 3.5 L V6 Gasoline Direct Injection Engine
Authors: Kawawa Satoshi , Tomitani Yuki , Nakashima Hiroaki , Imakita Akio , Taki Shotaro
Published: November 2023

A 3.5-L natural aspiration engine was developed to enhance the environmental performance of V6 engines to be used in Honda’s North American market.

This engine changes from the single overhead cam architecture for the cylinder head found in the previous engine to a double overhead cam architecture and adopted variable timing control intake and exhaust variable cylinder management for the valve system. This increased the degree of freedom in setting valve timing across the operating range compared to the past, increased the intake air volume in the high-load range, and realized reduction of pumping loss under low and medium load.

The intake port, combustion chamber, and piston shape related to combustion have been newly designed to enhance in-cylinder flow. In addition, while following the cooling structure of previous engine, water channels were installed between the exhaust valves and between the cylinder bores to enhance the cooling performance of the combustion chamber. These improvements have resulted in improved thermal efficiency while achieving the same or higher power performance of the previous engine.

High fuel pressure and injectors with reduced nozzle hole size were adopted for the fuel system in order to enhance emission performance. This in combination with multistage injection control realized atomization of the spray and shorter spray penetration distance. A vehicle equipped with this engine achieved LEV III and SULEV 30 standards as well as particulate matter of 1 mg/mile.

Methods used to reduce engine noise due to rapid combustion were increasing the stiffness of the intake manifold and adopting a mounting layout on top of the engine for the intake system, which functions as an engine cover. These methods achieved engine noise level on a par with previous engine.
Influence of Combustion Mode on Heat Loss Distribution in Gasoline Engines
Authors: Matsuda Hirotsugu , Uchida Kenji , Harada Yuji , Yamashita Hiroyuki
Published: November 2023

As a technology to reduce the heat loss of engines, heat insulation coating to the surface of combustion chamber has been received a lot of attention. In order to maximize the thermal efficiency improvements by the technology, it is important to clarify the location where heat insulation coating can reduce heat loss more effectively, considering the impact on abnormal combustion etc. In this study, transient behavior of wall heat flux distribution on the piston was analyzed using 3D Computational Fluid Dynamics (CFD) for three combustion modes (spark ignition combustion (SI), homogenous charge compression Ignition (HCCI) and spark controlled compression ignition (SPCCI)).
Numerical Investigation of Knocking in a Small Two-Stroke Engine with a High Compression Ration to Improve Thermal Efficiency
Authors: Eto Kuniyoshi , Kuboyama Tatsuya , Moriyoshi Yasuo , Yamada Toshio , Yamazaki Takahiro , Yamaguchi Shiro
Published: November 2023

This study aimed to achieve both a high compression ratio and low knock intensity in a two-stroke engine. Previous research has suggested that knock intensity can be reduced by combining combustion chamber geometry and scavenging passaging design for the same engine specifications with a compression ratio of 13.7. In this report, we investigate whether low knock intensity can be achieved at compression ratios of 14.4 and 16.8 by adjusting the combustion chamber geometry and scavenging passage design. As a result, the mechanism by which combustion chamber geometry and scavenging passage design change knock intensity was clarified.
Engine Knocking Detection by Measuring Cylinder Pressure, Combustion Flame, Vibration and Radiation Noise
Authors: Murase Michio , Kasahara Taro , Kuboyama Tatsuya
Published: November 2023

Knocking is an important issue in improving the efficiency of spark ignition engines. It can be detected by photographing with high-speed cameras or measuring in-cylinder pressure or engine vibration or engine radiation sound. However, these methods each have the problems for example sensor damage risk or necessity of machining the engine. In this paper, we propose the efficient measurement method and the effective evaluation method with the restricted measurement results for engine knocking detection by utilizing the simultaneous measurement results of knocking with these sensors.
Developing a numerical method for simulating physical and chemical processes that lead to LSPI
Authors: Mahmood Adnan , Hellier Paul
Published: November 2023

Low speed pre-ignition (LSPI) is a limiting phenomenon for several of the technologies being pursued as part of the low carbon agenda. To achieve maximum power density and efficiency engines are being downsized and turbocharged, while Direct- injection technologies are becoming ever more prominent. All changes that increase the propensity of LSPI. The low speed-high load operation envelope is limited due to LSPI. Hydrogen engines are also being explored, however, with such a low minimum enthalpy of ignition, LSPI is a major limitation to thermal efficiency. Several techniques are utilized in this study to investigate physical and physio-chemical aspects of lubricant initiated LSPI. Where possible attempts have been to validate methodologies or directional alignment with published data. The basis of the methodologies used is a validated 1D predictive combustion model of a single cylinder GTDI engine, that was used to provide simulation boundary conditions.

The study comprises of two parts; the first part of the study investigates the likelihood of hydrocarbon components within the lubricant causing LSPI. All aspects of hydrocarbons will be investigated including hydrodynamics behaviour between ring-liner, transport from crevice volume to combustion chamber, evaporation and reaction/heat release. A justification is provided for why lubricant hydrocarbons demonstrate ignition in rapid compression machines but not in engines.

The second part of the study investigates the behaviour of Ca and Mg based lubricant detergents inside an engine environment. With the use of a single particle ignition model a corroborated explanation is offered as to why LSPI occurs with Ca and not Mg. A sensitivity study is completed to assess how deviations in the assumed boundary conditions impact the time of ignition. The predicted heat release from a Ca particle is then represented inside a static air-fuel volume to observe the nature of heat propagation. Finally, the paper combines findings from the hydrocarbon and detergent studies to postulate a novel theory for why LSPI occurs at an appropriate timing to subsequently cause Mega Knock.