A non-linear quasi-3d model for air management modelling in engines

Resumen

Engine modelling has become an essential tool in the design of internal combustion engines, allowing considerable reductions in development time and cost. Classical design methodologies are based on prototype manufacturing and trial-and-error tests, but currently, most of those tests have been replaced by numerical computations, so that only the most promising design options are actually tested on engine bench. For years, one-dimensional gas dynamics codes in the time domain have offered sufficiently good solutions for modelling both engine performance and intake and exhaust noise. However, for a more demanding level of design, a 1D representation may not be sufficient to describe accurately the flow in certain elements. This is especially important in the case of silencers. In the case of duct junctions, the existence of complex 3D flow structures is what sets the applicability limit for a simple zero-dimensional description. In view of these limitations, the first option would typically be the use of a computational fluid dynamics (CFD) model; however, the application of such a model to a complete intake or exhaust system entails an excessive computational time. A possible compromise solution is given by quasi-3D models, based on three-dimensional schemes, but with certain simplifications able to significantly reduce the calculation time without excessively affecting the accuracy. Such solutions have become standard in commercial codes and have been successfully applied to silencers with perforated tubes and absorbing material, both in the linear acoustic regime and in real engine conditions, typically non-linear. The objective of this thesis is the development a new quasi-3D numerical method in a staggered-grid, based on the simplification of the momentum equation, to be included in an existing one-dimensional code. Such method however, is not hassle free. In particular, it is affected by the appearance of non-physical oscillations, specially near significant pressure gradients. From the literature review it is determined that this behaviour is typical among second-order schemes and it can be aggravated by the simplifications adopted. After researching the possible solutions to face this problem, three different flux limiters are developed, based on the MDT, FCT and TVD methodologies. In the case of the two latter methods, its effectiveness is well established for finite differences schemes, thus defining a clear improving line for quasi-3D models. Once the numerical method is defined and its stability assured, proper boundary conditions that allow its use must be developed. With this objective, a pressure pulse inlet and an anechoic termination boundary condition are developed, which allow the simulation of an impulse test rig. It should not be forgotten, however, that the ultimate objective is the connection with a one-dimensional code, therefore the compatibility of the quasi-3D numerical method created with the existing one-dimensional methods has to be tested, showing some preliminary results. Eventually, with a fully operative method, the validation process for the applications which it has been mainly developed for, takes place, namely, mufflers and duct junctions modelling. In the case of mufflers, increasingly complex devices are modelled, from constant section geometries to real geometry systems. The results obtained are validated with both linear and non-linear tools. In the case of duct junctions, the main objective is to establish the potential of the new numerical method against the traditional one-dimensional schemes, consequently, results from both approaches are compared to experimental measures, obtaining promising results.