柴油机喷嘴结构对喷雾特性的影响研究
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摘要
柴油机作为热效率最高的动力机械,其在未来很长一段时间内将继续保持交通运输领域主要动力的地位,但其发展受到了不断强化的燃油经济性和有害排放限值法规的挑战。柴油机的燃油喷射及雾化混合对于燃烧乃至柴油机的性能具有决定性的影响。因此,长期以来,对燃油喷雾机理的探索一直为国内外研究者所重视,并针对这一主题进行了大量研究。但燃油喷射雾化由于问题本身的复杂性,至今许多机理尚未被全面揭示,如喷嘴结构对喷雾特性的影响。本文针对这个问题,系统地分析和总结了柴油机喷嘴内部空穴流动及喷雾流场相关的试验和数值模拟理论,并采用比例放大透明喷嘴内空穴湍流高速摄影、基于同步辐射X射线的喷嘴结构精确测试、喷雾流场的PDPA和PIV测试等可视化试验和三维CFD数值模拟研究相结合的方法,开展了喷嘴结构对其内部空穴流动特性及喷雾特性影响的研究。主要结论如下：
(1)喷嘴内部空穴现象的发生与雷诺数没有直接的联系,而只与空穴数有关；随着喷孔直径的减小,空穴初生临界压力增加,小口径乃至原型喷嘴,其喷嘴内部较难出现空穴现象；柴油机喷嘴喷孔长径比和倾角以及针阀升程、压力室形状等几何结构因素都会影响其内部空穴流动特性；喷射燃料的物理特性对柴油机喷嘴空穴流动有重要影响,生物柴油比柴油更难出现空穴现象,生物柴油为获得良好雾化质量的喷射压力要高于柴油。
(2)基于多相流和气泡动力学理论,建立了喷嘴内空穴流动的三维数值计算模型,并结合比例放大透明喷嘴空穴流动可视化试验数据验证了该模型可以较为准确地模拟柴油机喷油嘴内空穴流动现象。对不同结构参数的喷嘴内部空穴流动特性进行了全面深入的数值模拟分析,分析了燃油喷射压力、喷射背压、喷孔直径、喷孔长度、喷孔入口圆角半径、喷孔倾斜角等几何特征参数、喷嘴不同压力室结构及针阀偏心等因素对喷嘴内部空穴流动的影响,发现喷孔入口保持锐边的喷嘴的喷雾特性要优于圆角喷孔入口的喷嘴,喷油压力的提高能很大程度上改善喷雾特性以及改进型喷嘴流动的综合特性好于VCO型和STD型喷嘴的结论。
(3)采用同步辐射X射线技术可以非破坏性地获取柴油机喷油器喷孔内部准确的三维几何结构,对某油嘴的实验发现,其各喷孔圆周方向分布基本均匀,进出口界面面积基本相等,喷孔界面未出现收缩和膨胀,存在的加工误差较小,但各个喷孔的长度并不相等,上下圆角半径也存在着较大区别；基于PDPA技术的喷雾高速摄影研究发现,豆油甲酯/O#柴油混合燃油的喷雾锥角存在“驼峰”变化现象,轴向速度是影响喷雾特性的关键因素,直接对液相贯穿距变化产生显著影响,也是影响径向速度的决定因素,二者变化趋势大致相同,轴向速度越大,相应的径向速度越大,表现出的喷雾锥角就越大；基于PIV技术的喷雾特性实验发现,燃油的喷射压力的提升有助于油滴与周围环境进行动量交换,在一定范围内燃油压力越高,油束动量越大,喷雾场内动量交换越广泛。
(4)建立了基于ELSA法的喷雾耦合模拟方法,在喷孔出口近场燃油稠密区采用Euler法计算,而远场喷雾则采用Lagrangian法计算,并耦合喷嘴内空穴流动的影响,得到更加准确的模拟结果。
As the highest thermal efficiency of power machinery, diesel engines will maintain the essential position of the driving force in the field of transportation for a long time in the future. But due to the rising cost of fossil fuels and hazardous emissions, its developments have been limited and challenged. In diesel engines, fuel injection, the shape of spray and quality of atomization strongly affect the combustion and the performance of engine. Therefore, the research for fuel spray mechanism attracted more attention of domestic and foreign researchers. But due to complexity of spray, a lot of mechanism has not been fully revealed so far, such as the effect of injector geometry. The test and numerical simulation of cavitation flow in the nozzle hole and the spray flow field have been analyzed and summarized fully and systematically. Combining methods of scaled high-speed photography about the cavitation turbulence in the transparent nozzle, accurate test of injector geometry by synchrotron radiation X-ray, PDPA and PIV test of spray flow and three dimensional CFD numerical simulation to carry out researches about the effect of injector geometry on the performance of the cavitation flow and spray. The main conclusions are as flows:
(1) There is no direct link between the occurrence of cavitation flow and the Reynold number, but the cavitation number. With the reduction of the nozzle diameter, the hole primary critical pressure increases, it is difficult to occur cavitation in small-caliber or prototype nozzle. The tip orifice aspect ratio and inclination and needle lift pressure chamber will affect the performance of the cavitation flow. The physical characteristics of the fuel has an important influence on the cavitation flow in the nozzle hole, biodiesel appears much harder than diesel to occur cavitation. So to obtain good spray quality, biodiesel needs higher injection pressure.
(2) Based on the theory of Multiphase flow and bubble dynamics, three-dimensional numerical model of the cavitation flow in the nozzle hole was builded, and combined with the date of visualization test in scaling transparent nozzle holes to simulate the cavitation flow accurately. In this study, the effects of nozzle geometry on the internal nozzle flow were investigated by numerical simulation. And found that the sharp edge of the inlet has superior spray performance than fillet one. Improvement of fuel injection pressure can greatly improve performance of the spray and the nozzle flow.
(3) Synchrotron radiation X-ray technology can access accurate three-dimensional geometry non-destructively. Experiments found that the circumferential direction of each nozzle hole has substantially uniform distribution, import and export interfacial area is basically the same, and contraction or expansion does not appear on the spray hole interface and mismachining tolerance is small, but not equal to the length of each nozzle hole and there is a big difference between the upper and lower corner radius. Based on the PDPA technology of spray high-speed photography study found that spray cone angle "hump" of soybean oil methyl ester/0#diesel hybrid fuel has change phenomenon. The axial velocity is a key factor affecting the spray performance and also the determinants of the radial velocity, higher axial velocity leads to higher radial velocity and bigger spray cone angle. Based on PIV technology, it is found that the enhancement of the injection pressure contributes to the momentum exchange between oil droplets and the surrounding environment.
This paper puts forward a ELSA (Euler-Lagrangian Spray and Atomization) spray simulation methods, Euler method is used in the orifice outlet near-field fuel dense area, and the far-field spray uses Lagrangian method, and coupling the cavitation flow in nozzle hole to get a more accurate simulation results.
(1)喷嘴内部空穴现象的发生与雷诺数没有直接的联系,而只与空穴数有关；随着喷孔直径的减小,空穴初生临界压力增加,小口径乃至原型喷嘴,其喷嘴内部较难出现空穴现象；柴油机喷嘴喷孔长径比和倾角以及针阀升程、压力室形状等几何结构因素都会影响其内部空穴流动特性；喷射燃料的物理特性对柴油机喷嘴空穴流动有重要影响,生物柴油比柴油更难出现空穴现象,生物柴油为获得良好雾化质量的喷射压力要高于柴油。
(2)基于多相流和气泡动力学理论,建立了喷嘴内空穴流动的三维数值计算模型,并结合比例放大透明喷嘴空穴流动可视化试验数据验证了该模型可以较为准确地模拟柴油机喷油嘴内空穴流动现象。对不同结构参数的喷嘴内部空穴流动特性进行了全面深入的数值模拟分析,分析了燃油喷射压力、喷射背压、喷孔直径、喷孔长度、喷孔入口圆角半径、喷孔倾斜角等几何特征参数、喷嘴不同压力室结构及针阀偏心等因素对喷嘴内部空穴流动的影响,发现喷孔入口保持锐边的喷嘴的喷雾特性要优于圆角喷孔入口的喷嘴,喷油压力的提高能很大程度上改善喷雾特性以及改进型喷嘴流动的综合特性好于VCO型和STD型喷嘴的结论。
(3)采用同步辐射X射线技术可以非破坏性地获取柴油机喷油器喷孔内部准确的三维几何结构,对某油嘴的实验发现,其各喷孔圆周方向分布基本均匀,进出口界面面积基本相等,喷孔界面未出现收缩和膨胀,存在的加工误差较小,但各个喷孔的长度并不相等,上下圆角半径也存在着较大区别；基于PDPA技术的喷雾高速摄影研究发现,豆油甲酯/O#柴油混合燃油的喷雾锥角存在“驼峰”变化现象,轴向速度是影响喷雾特性的关键因素,直接对液相贯穿距变化产生显著影响,也是影响径向速度的决定因素,二者变化趋势大致相同,轴向速度越大,相应的径向速度越大,表现出的喷雾锥角就越大；基于PIV技术的喷雾特性实验发现,燃油的喷射压力的提升有助于油滴与周围环境进行动量交换,在一定范围内燃油压力越高,油束动量越大,喷雾场内动量交换越广泛。
(4)建立了基于ELSA法的喷雾耦合模拟方法,在喷孔出口近场燃油稠密区采用Euler法计算,而远场喷雾则采用Lagrangian法计算,并耦合喷嘴内空穴流动的影响,得到更加准确的模拟结果。
As the highest thermal efficiency of power machinery, diesel engines will maintain the essential position of the driving force in the field of transportation for a long time in the future. But due to the rising cost of fossil fuels and hazardous emissions, its developments have been limited and challenged. In diesel engines, fuel injection, the shape of spray and quality of atomization strongly affect the combustion and the performance of engine. Therefore, the research for fuel spray mechanism attracted more attention of domestic and foreign researchers. But due to complexity of spray, a lot of mechanism has not been fully revealed so far, such as the effect of injector geometry. The test and numerical simulation of cavitation flow in the nozzle hole and the spray flow field have been analyzed and summarized fully and systematically. Combining methods of scaled high-speed photography about the cavitation turbulence in the transparent nozzle, accurate test of injector geometry by synchrotron radiation X-ray, PDPA and PIV test of spray flow and three dimensional CFD numerical simulation to carry out researches about the effect of injector geometry on the performance of the cavitation flow and spray. The main conclusions are as flows:
(1) There is no direct link between the occurrence of cavitation flow and the Reynold number, but the cavitation number. With the reduction of the nozzle diameter, the hole primary critical pressure increases, it is difficult to occur cavitation in small-caliber or prototype nozzle. The tip orifice aspect ratio and inclination and needle lift pressure chamber will affect the performance of the cavitation flow. The physical characteristics of the fuel has an important influence on the cavitation flow in the nozzle hole, biodiesel appears much harder than diesel to occur cavitation. So to obtain good spray quality, biodiesel needs higher injection pressure.
(2) Based on the theory of Multiphase flow and bubble dynamics, three-dimensional numerical model of the cavitation flow in the nozzle hole was builded, and combined with the date of visualization test in scaling transparent nozzle holes to simulate the cavitation flow accurately. In this study, the effects of nozzle geometry on the internal nozzle flow were investigated by numerical simulation. And found that the sharp edge of the inlet has superior spray performance than fillet one. Improvement of fuel injection pressure can greatly improve performance of the spray and the nozzle flow.
(3) Synchrotron radiation X-ray technology can access accurate three-dimensional geometry non-destructively. Experiments found that the circumferential direction of each nozzle hole has substantially uniform distribution, import and export interfacial area is basically the same, and contraction or expansion does not appear on the spray hole interface and mismachining tolerance is small, but not equal to the length of each nozzle hole and there is a big difference between the upper and lower corner radius. Based on the PDPA technology of spray high-speed photography study found that spray cone angle "hump" of soybean oil methyl ester/0#diesel hybrid fuel has change phenomenon. The axial velocity is a key factor affecting the spray performance and also the determinants of the radial velocity, higher axial velocity leads to higher radial velocity and bigger spray cone angle. Based on PIV technology, it is found that the enhancement of the injection pressure contributes to the momentum exchange between oil droplets and the surrounding environment.
This paper puts forward a ELSA (Euler-Lagrangian Spray and Atomization) spray simulation methods, Euler method is used in the orifice outlet near-field fuel dense area, and the far-field spray uses Lagrangian method, and coupling the cavitation flow in nozzle hole to get a more accurate simulation results.
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