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In this article, the effects of increasing spray cone angle and turbulence intensity on the performance and emission of heavy-duty diesel engine has been examined in two separate stages using AVL-Fire CFD code. First, the injector and its spray have been simulated with various geometries. In this step, the Eulerian-Eulerian model has been applied for injector simulation and the Eulerian -Lagrangian model has been applied for spray simulation. The numerical results of this step indicate that creating swirly flow inside the nozzle decreasing penetration length while, fuel spray cone angle increasing during the injection process. In the subsequent step, the heavy-duty diesel engine has been simulated with its conventional and different nozzle hole geometries. In this step, the Eulerian-Lagrangian model has been applied to simulate the engine cycle. The numerical results of this step show that the nozzle with spiral rifling like guides has better performance and lower emission compared to other nozzle geometries. In this case, the fuel consumption is decreasing 32% than cylindrical nozzle hole, while the engine power and its torque increasing 63%. In addition, the amount of nitrogen oxide (NOx) and carbon monoxide (CO) for the spiral convergent conical nozzle geometry reducing 15% and 30% respectively than cylindrical nozzle hole while engine has no soot emission problem. Diesel injector and engine CFD results and experimental data have been validated from previous researches.

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