ECN Spray G injector: Numerical modelling of flash-boiling breakup and spray collapse

Abstract

Flash boiling is the sudden change from liquid to vapour phase and in IC engines it typically occurs during the injection process with a gasoline direct injection (GDI) setup and when high fuel temperatures result in saturation pressures higher than the in-cylinder ones. The flash boiling, due to the complex evolution of a multi-phase flow and a rapid droplet vaporisation, promotes spray atomisation and affects significantly the spray structure and fuel–air mixture formation, with consequences for the engine performance and pollutant emissions. Hence, a deep knowledge of such phenomenon is required to improve the combustion process and reduce the pollutant production. The breakup mechanism of a superheated spray is quite different from a regular one, because it features the nucleation and growth of bubbles within liquid droplets. In this paper, an innovative flash-boiling breakup model was embedded in a Eulerian–Lagrangian two-phase solver using OpenFOAM library. The model assigns to the droplets a radial velocity component due to the bubble explosion, making it capable of reconstructing the spray expansion. The code was tested using experimental data of the ECN Spray G injector covering various thermodynamic conditions. The numerical model achieves a good level of agreement with the experimental data and, in particular, it is able to reconstruct the spray collapse. Besides, it provides useful information regarding parameters that are intrinsically difficult to measure experimentally.