Fuel air mixing analysis in a multiport fuel injection (MPFI) spark ignition (S.I.

) engine
INTERN REPORT ON COMPUTATIONAL FLUID DYNAMICS

Submitted in partial fulfillment of requirements for the degree of BACHELOR OF TECHNOLOGY in MECHANICAL ENGINEERING.
SUBMITTED BY Md Shahid(11M177) Subham k Burnwal(11M257)

DEPARTMENT OF MECHANICAL ENGINEERING National Institute of Technology Karnataka, Surathkal, Mangalore- 575025. September 2013

ACKNOWLEDGEMENT
Before everything I heartily acknowledge Professor G. N. Kumar for believing in us, and giving this project which proved to be really challenging and equally enlightening, besides it required our intense involvement. It compelled us for real brainstorming and continuous effort. Secondly I thank our friend Mr. Ravi Teja for making us do it all, and really helping us in time of need. For being an awesome instructor, to help us to clear any kind of problem we used to face during the work progress without the slightest of difficulty and hesitation. Last but not the least I thank god the supreme power the omnipotent and omniscient who has been there watching us do our job, for being the supreme guide; the incessant source of everything.

Md Shahid Subham k Burnwal

ABSTRACT
Flow of the fuel and air into the cylinder of an engine requires pre mixing of the fuel-air mixture into the inlet manifold of the engine. The performance of an engine depends largely on the proportion and efficiency by which the mixing takes place. Conventionally carburetors were used to meter the flow, but they were not very accurate. Hence, a more effective way for fuel injection called the multiport fuel injection was introduced. MPI system is accurate and leads to effective mixing of the fuel and air. The present study is aimed at Modeling and simulation of inlet manifold of an MPI engine. With the use of Computational Fluid Dynamics (CFD) the total work of the multi-dimensional modeling and analysis of flow simulation of the mixture in an inlet manifold, that otherwise takes some weeks to months of work may be made possible in some days. The tools used in making this attempt possible were solidworks 2012 for the geometry and fluid flow analysis using FLUENT solver in workbench in ANSYS 14.0.

KEYWORDS
Inlet manifold, Fuel Injector, Carburetor, ANSYS, CFD, I.C. Engines.

TABLE OF CONTENTS pages

Acknowledgement Abstract Keywords Table of contents 1. Introduction 1.a - carburetor Disadvantages of carburetors vii 1.b - fuel injector Benefits of fuel injectors 1.c - CFD (general) 1.d- Ansys 2. Objectives 3. Methodology 4. Results and dissensions 5. Conclusion 6. References vii ix I ii ii iii iv

1.INTRODUCTION
Ecological and economical issues have always challenged us to try and innovate, to bring newer and efficient technologies. Traditional internal combustion engines used carburetor to fire fuel into their cylinder.

1. (A) - Carburetor
A carburetor is a device that blends air and fuel in an internal combustion engine. It works on the Bernoullis principle; the faster air moves, the lower its static pressure and the higher its dynamic pressure. Carburetor is essentially just a tube through which filtered air flows from the automobiles air intake. Within this tube, there is a narrowing, or a venturi, where a vacuum is created. There is a small hole in the narrowing called a jet which is fed fuel via the float chamber. The float chamber is a container filled with an amount of fuel that is set by a float. The vacuum created in the venturi draws in fuel from the float chamber, which is at ambient pressure. The faster the filtered air comes in through the carburetor throat, the lower the pressure in the venturi. This leads to a higher pressure difference between the venturi and the float chamber, and thus more fuel flows out of the jet and mixes with the airstream.

Older engines used updraft carburetors, where the air enters from below the carburetor and exits through the top. This had the advantage of never flooding" the engine, as any liquid fuel droplets would fall out of the carburetor instead of into the intake manifold. It also lent itself to use of an oil bath air cleaner, where a pool of oil below a mesh element below the carburetor is sucked up into the mesh and the air is drawn through the oilcovered mesh; this was an effective system in a time when paper air filters did not exist.

In the late 1930s, downdraft carburetors were the most popular types used. Then the sidedraft carburetors replaced downdraft as free space in the engine bay decreased. Downstream of the jet, there is a throttle valve that opens when the accelerator pedal is engaged. This throttle valve restricts how much air enters the carburetor. If you push the gas pedal all the way down, the throttle valve opens fully, allowing air to flow more quickly through the carburetor, creating a bigger vacuum in the venturi, sending more fuel into the engine, creating more power. At idle, the throttle valve is fully shut, but there is an idling jet that bypasses the throttle valve and sends a set amount of fuel and air into the engine. Without an idling jet, the engine would shut off if the throttle were not activated by the driver during idle.

Disadvantages
The main disadvantages of a carburetor's operation are as: With carburetors complexity, the car owner is subject for more

expenses because it needs to be cleaned and opened up regularly to obtain outstanding fuel economy; It cannot meter the correct AFR (air fuel ratio) needed to obtain

maximum power; More fuels are consumed since carburetors are heavier; More air emissions; Not-so-good use of fuel since normally each car has one carburetor

for all of its cylinders; Maintenance cost of carburetor is higher.

1. (B)- Fuel Injector

Fuel injection systems are becoming more popular nowadays. There are two different kinds of fuel injection techniques; Modern internal combustion engines use: Single point injection Continuous injection Central port injection

Multi port fuel injection (MPFI) Gasoline direct injection (GDI) swirl injection.

Multi port fuel injection system is the most popular of all it atomizes the fuel by forcibly pumping it through a small nozzle under high pressure. The electronics used in the system will calculate this information and constantly adjust accordingly. Present I.C. Engines equipped with multi port fuel injector sprays fuel directly through the intake valve or valves into the combustion chamber. Here each injector is activated separately by wire. One can measure how

much gas an engine needs by how much air it is sucking in. Once the engine starts, the measuring of air begins. Early fuel injection systems used a vane system, which was basically a flap inside a tube, to measure how much air was being sucked. There are lots and lots of variations to fuel injection systems. Such as electronic fuel injection, mechanical fuel injection, systems with one oxygen sensor systems with four oxygen sensors , etc. with injector right into the intake port just above each cylinder's intake valve, instead of at a central point.

Benefits of fuel injectors

The main benefits to using direct injection is that the amount of fuel and air can be perfectly released and then injected into the cylinder according to the engine load conditions. This type of controlled fuel injection results in a higher power output, Greater fuel efficiency and much lower emissions. Not only can fuel injection make more power, it can be manipulated to run smoother, run better cold and hot, easier starts, and better fuel mileage.

1. (C)- CFD (general)

Computational fluid dynamics, usually abbreviated as CFD, is a branch of fluid mechanics that uses numerical methods and algorithms to solve and analyze problems that involve fluid flows. It provides qualitative sometimes quantitative prediction of fluid flow by means of

 Mathematical modeling (Partial differential equations) Numerical methods (discretization and solution techniques) Software toos (Solver, pre- and postprocessing utilities) Computers are used to perform the calculations required to simulate the interaction of liquids and gases with surfaces defined by boundary conditions. With high-speed supercomputers, better solutions can be achieved. Ongoing research yields software that improves the accuracy and speed of complex simulation scenarios such as transonic or turbulent flows. The fundamental basis of almost all CFD problems are the NavierStokes equations, which define any single-phase (gas or liquid, but not both) fluid flow. These equations can be simplified by removing terms describing viscous actions to yield the Euler equations. Further simplification, by removing terms describing vorticity yields the full potential equations. Finally, for small perturbations in subsonic and supersonic flows (not transonic or hypersonic) these equations can be linearized to yield the linearized potential equations.

Uses of CFD
architects to design comfortable and safe living environments Designers of vehicles to improve the aerodynamic characteristics Chemical engineers to maximize the yield from their equipment

 Petroleum engineers to devise optimal oil recovery strategies Surgeons to cure arterial diseases (computational hemodynamics) Meteorologists to forecast the weather and warn of natural disasters Safety experts to reduce health risks from radiation and other hazards Military organizations to develop weapons and estimate the damage CFD practitioners to make big bucks by selling colorful pictures

Experiments vs. Simulations

CFD gives an insight into ow patterns that are difficult, expensive or impossible to study using traditional (experimental) techniques.

Fluid characteristics
Macroscopic properties: Density(rho), viscosity(mu), pressure(p), temperature(T), velocity(v). Classification of fluid flow: Viscous, inviscid, compressible, incompressible, steady, unsteady, laminar, turbulent, single-phase, multi-phase. The reliability of CFD simulations is greater For laminar/slow flows than for turbulent or fast ones For single-phase flows than for multi phase flows For chemically inert system than for reactive flows.

CFD analysis process

1. Problem statement- information about the ow 2. Mathematical model- IBVP = PDE + IC + BC 3. Mesh generation- nodes/cells, time instants 4. Space discretization- coupled ODE/DAE systems 5. Time discretization- algebraic system Ax = b

6. Iterative solver- discrete function values 7. CFD software- implementation, debugging 8. Simulation run- parameters, stopping criteria 9. Post processing- visualization, analysis of data 10. Verication- model validation / adjustment

1. (D)- Ansys
ANSYS is a general purpose software, used to simulate interactions of all disciplines of physics, structural, vibration, fluid dynamics, heat transfer and electromagnetic for engineers. So ANSYS, which enables to simulate tests or working conditions, enables to test in virtual environment before manufacturing prototypes of products. Furthermore, determining and improving weak points, computing life and foreseeing probable problems are possible by 3D simulations in virtual environment. ANSYS software with its modular structure as seen in the table below gives an opportunity for taking only needed features. ANSYS can work integrated with other used engineering software on desktop by adding CAD and FEA connection modules.

ANSYS can import CAD data and also enables to build a geometry with its "preprocessing" abilities. Similarly in the same preprocessor, finite element model (a.k.a. mesh) which is required for computation is generated. After defining loadings and carrying out analyses, results can be viewed as numerical and graphical. ANSYS can carry out advanced engineering analyses quickly, safely and practically by its variety of contact algorithms, time based loading features and nonlinear material models. ANSYS Workbench is a platform which integrates simulation technologies and parametric CAD systems with unique automation and performance. The power of ANSYS Workbench comes from ANSYS solver algorithms with years of experience. Furthermore, the object of

ANSYS Workbench is verification and improving of the product in virtual environment. ANSYS Workbench, which is written for high level compatibility with especially PC, is more than an interface and anybody who has an ANSYS license can work with ANSYS Workbench. As same as ANSYS interface, capacities of ANSYS Workbench are limited due to possessed license.

2.OBJECTIVES
This project is an attempt to study the behavior of the mixing of fuel into the inlet manifold taking into consideration the design of the manifold. Using numerous experimental and Reynolds-averaged NavierStokes (RANS) based numerical investigations concentrated on gaining insight into the mean behavior of the spray in IC-engines.

3.METHODOLOGY
At present most inlet manifolds are designed by trial and error, method or study through prototypes that takes much time and effort to reach an optimal design and that there is a lack of a systematic process. To help design an inlet manifold of a higher efficiency, which would require a reduction in cost in the experimental setup and study, is the need of the

hour. Through the advancement of the computer system performance it is made possible to run softwares that can analyze to give results of even the most complicated real life situations which are impossible to fabricate. In this study, to develop a new framework for the design of inlet manifolds, characteristics of ow patterns inside it are investigated by using computational uid dynamics (CFD). In addition to analysis of ow patterns, a CFD-based optimal design procedure is proposed. The design methodology can be depicted in the form of this flowchart

RESULT AND DISSENSIONS

1. Import the solid model into ansys 14.0 fluent workbench
The model of the inlet manifold is made with the help of solidworks. The model is then saved in the igs format. This model then can be imported in ansys workbench environment. The model is then imported in the ansys workbench and then it is genereated to provide us the model in design modeler. Then the model can be used to be meshed by the Ansys mesher.

Design modeler (Ansys workbench) 2. Generate mesh

once the design modeler has generated the solid body it is then meshed using the mesher in Ansys workbench. The mesher provides us with various parameters to mesh the model. After setting the

various parameters like sizing of mesh, type of analysis to be made, solver to be used for calculation, etc we go fo meshing the material.

The 3d model is taken as fluid

Model after getting meshed

3. Set up the boundary conditions

After the model is been meshed into the Ansys mesher, the various conditions are implied to the model into the fluent environment. The various conditions include; materials, phases, cell zone conditions, boundary conditions, etc.

Fluent environment window 4. Solve using Fluent solver

Once all the conditions have been implied onto the model then it is ready to be solved to give results. The fluent solver generates the solution after the number of iterations is mentioned, solution method is specified and initialization of the various variables is made.

Graph showing calculation done by fluent 5. Obtain result using fluid flow CFD Post
After the solution is been done by the fluid flow fluent solver next we proceed to obtaining the various forms of results that can be obtained in the CFD post. The variation of various parameters like pressure, phase velocity, stream lines of inlet air, animation of fluid molecoles flow, etc.

Variation of pressure

Contour of velocity
ccc m

Total pressure contour

3D streamline of inlet air

Particle animation of fluid mixture

Velocity vector plot of the fluid

CONCLUSION
The investigation and analysis of the in-cylinder ow motion characteristics, during the intake stroke, is numerically carried out by using a CFD code This project aims at providing a virtual prototype for the analysis of a real world component (i.e. the inlet manifold) of a four stroke I.C. Engine, the analysis of which on the other hand is a real challenge otherwise. This method is not only a very efficient way to a really difficult problem but is also very effective, economical, efficient and precise approach to such a problem.

REFERENCES
CFD-based optimal design of manifold in plate-n

microdevices - Department of Chemical Engineering, Kyoto University, Katsura Campus, Nishikyo-ku, Kyoto 615-8510, Japan Received 31 July 2003; accepted - 28 October 2003. Inuence of intake manifold design on in-cylinder ow and engine performances in a bus diesel engine converted to LPG gas fuelled, using CFD analyses and experimental investigations- 2011.- (Aug. 03, 2013) Rapid CFD Simulation of Internal Combustion Engines 1999- Citeseer. - (Aug. 23, 2013)
Computational Fluid Dynamics- The Basics with

Applications John D Anderson, Jr (Aug. 28, 2013)

 The Wikipedia- carburetor http://en.wikipedia.org/wiki/Carburetor - (Aug. 21, 2013) The Wikipedia Fuel injector http://en.wikipedia.org/wiki/Fuel_injection (Sept. 11, 2013) The Wikipedia- Computational fluid dynamics

http://en.wikipedia.org/wiki/Computational_fluid_dynami cs - (Sept. 20, 2013)