The consequences of geometry alterations in a Diesel injector caused by cavitation erosion are investigated with numerical simulations. The differences in the results between the nominal design geometry and the eroded one are analyzed for the internal injector flow and spray formation. The flow in the injector is modeled with a 3-phase Eulerian approach using a compressible pressure-based multiphase flow solver. Cavitation is simulated with a non-equilibrium mass transfer rate model based on the simplified form of the Rayleigh-Plesset equation. Slip velocity between the liquid-vapor mixture and the air is included in the model by solving two separate momentum conservation equations. The eroded injector is found to result to a loss in the rate of injection but also lower cavitation volume fraction inside the nozzle. The injected sprays are then simulated with a Lagrangian method considering as initial conditions the predicted flow characteristics at the exit of the nozzle. The obtained results show wider spray dispersion for the eroded injector and shorter spray tip penetration.

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Presented are two approaches for coupled simulations of the injector flow with spray formation. In the first approach the two-fluid model is used within the injector for the cavitating flow. A primary breakup model is then applied at the nozzle orifice where it is coupled with the standard discrete droplet model. In the second approach the Eulerian multi-fluid model is applied for both the nozzle and spray regions. The developed primary breakup model, used in both approaches, is based on locally resolved properties of the cavitating nozzle flow across the orifice cross section. The model provides the initial droplet size and velocity distribution for the droplet parcels released from the surface of a coherent liquid core. The major feature of the predictions obtained with the model is a remarkable asymmetry of the spray. This asymmetry is in agreement with the recent observations at Chalmers University where they performed experiments using a transparent model scaled-up injector. The described model has been implemented into AVL FIRE computational fluid dynamics code which was used to obtain all the presented results.

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a b s t r a c tThis research investigates high pressure diesel fuel injection into the combustion chamber by performing computational simulations using the Euler-Eulerian multiphase approach. Six diesel-like conditions were simulated for which the liquid fuel jet was injected into a pressurised inert environment (100% N 2 ) through a 205 lm nozzle hole. The analysis was focused on the liquid jet and vapour penetration, describing spatial and temporal spray evolution. For this purpose, an Eulerian multiphase model was implemented, variations of the sub-model coefficients were performed, and their impact on the spray formation was investigated. The final set of sub-model coefficients was applied to all operating points. Several simulations of high pressure diesel injections (50, 80, and 120 MPa) combined with different chamber pressures (5.4 and 7.2 MPa) were carried out and results were compared to the experimental data. The predicted results share a similar spray cloud shape for all conditions with the different vapour and liquid penetration length. The liquid penetration is shortened with the increase in chamber pressure, whilst the vapour penetration is more pronounced by elevating the injection pressure. Finally, the results showed good agreement when compared to the measured data, and yielded the correct trends for both the liquid and vapour penetrations under different operating conditions.