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Analysis and modification of EF7 engine cooling channel

Number of pages: 154 File Format: word File Code: 32615
Year: 2016 University Degree: Master's degree Category: Biology - Environment
Tags/Keywords: analysis - Combustion engines - cooling - EF7 - engine - Engine cooling - Heat engines - heat transfer - Internal combustion engines
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  • Summary of Analysis and modification of EF7 engine cooling channel

    Doctoral Dissertation

    Energy Conversion Trend

    Abstract

    One ??of the most important topics in internal combustion engines is the issue of heat transfer in them; Because almost one-third of the energy produced inside the combustion chamber is removed through engine cooling. The heat transfer of internal combustion engines is important from various aspects, including protecting the materials used in the sensitive parts of the engine against melting or deformation. Among the sensitive areas of the engine that are at risk due to high heat flux is the area between the smoke valves and around the spark plug. Lack of proper cooling in these areas can lead to gas leakage from the combustion chamber by changing the shape of the smoke valve seat and resulting in a loss of engine power and torque. The purpose of this thesis is to investigate the existing cooling system of the national EF7 engine and correct the improper cooling around the smoke valve in this engine, which in some cases has led to the distortion of the seat of the smoke valve. In this regard, first a one-dimensional and three-dimensional flow analysis and then a three-dimensional thermal analysis of the cooling flow in the engine passage was done. In order to ensure the numerical solution of the flow in the motor channel, the experimental method of PIV [1] was used. In the PIV method used, a transparent Plexy glass cylinder head and a high-speed camera were used to observe and measure the speed in the water channels of the engine cylinder head. In order to solve the cooling problem, two solutions were presented in this treatise. The first solution is to change the flow geometry by changing the coolant inlet and outlet pattern, and the second solution is to effectively use the boiling phenomenon in the engine cooling channel. In the first proposed solution, three different strategies were presented for the cooling entry and exit pattern. The comparison of the cooling speed at the critical cooling points in all three strategies showed that the first strategy can satisfy the desired cooling goals without the need to spend a lot of money, with the least necessary changes and the possibility of implementation[2]. Regarding the use of welding, first, an experimental device was built that was capable of creating high heat fluxes that occur in the engine. Using this device, the conditions of the phenomenon of current boiling in the engine were simulated. Then, based on the experimental data extracted from this device, a precise relationship was derived for modeling the boiling heat transfer. At this stage, the heat flux passing through different areas of the water channel was obtained using numerical simulation and three-dimensional thermal solution of the flow inside the cooling channel. With the heat fluxes and the boiling heat transfer relationship in hand, the necessary speed to use the boiling potentials in heat transfer was extracted. Although the tests and calculations carried out indicate the high potential of the boiling phenomenon in increasing the heat transfer coefficient and heat removal from the critical points of the engine, its implementation in this engine will have the necessary efficiency when a general review of the cooling path is carried out, which requires significant expenditure.

    1- The importance of heat transfer in internal combustion engines

    Internal combustion engines are heat engines. which convert the chemical energy of the fuel into mechanical energy. One of the most important issues in internal combustion engines is the issue of heat transfer in them. Heat transfer of internal combustion engines is important from various aspects. One of these cases is to protect the materials used in the sensitive parts of the engine against melting or deformation due to the design limitations of the materials. Another thing is to improve the performance [1] of the engine; Because almost one-third of the energy produced inside the combustion chamber is removed through engine cooling [1] and if this amount can be reduced, it will actually increase the useful power of the engine. Also, one of the most important sources of pollution in internal combustion engines is the engine's warm-up time [2], and the issue of cooling plays an effective role in reducing or increasing the mentioned time and subsequently reducing or increasing the engine's output pollutants.Another case of the importance of engine heat transfer is the fast and growing movement of internal combustion engines in the direction of increasing power and miniaturization[3] of the engine, in which the cooling system plays an undeniable role; Because producing more power in internal combustion engines with smaller sizes causes more heat flux to be imposed on engine components and parts, in which case, some sensitive points of the engine that are exposed to more heat flux - such as the area between the smoke valves and around the spark plug - sometimes become troublesome and require more precision in the design of the cooling system. Among other aspects of the importance of heat transfer in the engine, we can mention the improvement of the lubrication performance and the reduction of the impact phenomenon[4]. According to all these cases, the need for better and more accurate cooling of modern engines has always been introduced as one of the basic needs in engine design.

    National EF7 engine is a four-cylinder 16-valve gas-burning base engine that was designed and built by Iran Khodro Engine Design and Production Company in cooperation with FEV Germany. Despite the very good features of this engine, in some cases, some disadvantages have also been reported for it. Among these disadvantages are the reports that have been reported about the distortion of the smoke valve seat in this engine. This issue, which indicates poor cooling in these areas, can lead to gas leakage from the combustion chamber, resulting in loss of power and torque. The purpose of this thesis is to examine this problem and provide solutions to solve this problem.

    The released energy of the fuel in an internal combustion engine is removed in three ways during a work cycle. These three ways are: the mechanical power produced, the energy of the hot gases coming out of the engine and heat transfer through the walls. If the exit of part of the energy that takes place through the walls is not done well, problems such as damage to the parts, impact phenomenon and so on. will follow In the following, the methods of increasing the heat transfer power of the engine through the walls will be introduced.

    1-2- Methods of improving the performance of the cooling system

    Internal combustion engines are divided into two general parts in terms of cooling; Air-cooled engines and liquid-cooled engines. This liquid can be water or a mixture of water and ethylene glycol or any other liquid. Therefore, the principles of internal combustion engine cooling are based on displacement heat transfer.

  • Contents & References of Analysis and modification of EF7 engine cooling channel

    List:

     

    List of bugs.

    List of tables. A

    list of symptoms. Chapter 1: Preface. 1

    1-1- The importance of heat transfer in internal combustion engines. 2

    1-2- Methods of improving the performance of the cooling system. 3

    Chapter Two: Background of studies. 6

    2-1- Introduction. 7

    2-2- Changing the flow geometry. 7

    2-3- The background of precise cooling studies. 9

    2-4- boiling. 20

    2-5- The background of boiling studies in internal combustion engines. 25

    The third chapter: Experimental studies. 46

    3-1- Introduction. 47

    3-2- Boiling laboratory device. 47

    3-2-1- Reservoir. 48

    3-2-2- tank heater. 48

    3-2-3- Pump. 49

    3-2-4- three-way valve. 49

    3-2-5- pressure gauge. 49

    3-2-6- channel. 50

    3-2-7 Rotameter. 50

    3-2-8 copper coil. 51

    3-2-9- Test section. 51

    3-2-10- copper block. 52

    3-2-11- Cylindrical heater. 52

    3-2-12- PTFE insulation. 52

    3-2-13- Heat transfer oil. 53

    3-2-14- Rheosta 53

    3-2-15- Thermocouple. 54

    3-2-16- Vector data system 54

    3-2-17- Sanding 54

    3-2-18- Roughness gauge. 55

    3-2-19- Relay and controller. 56

    3-3- The results of the current boiling device. 57

    3-3-1- Experimental diagrams of boiling heat transfer. 57

    3-3-2- Error analysis 61

    3-4- Laboratory study of fluid movement using PIV method. 62

    3-4-1- Introduction to PIV method. 63

    3-4-2- The components used in the PIV test for the cylinder head of the internal combustion engine. 65

    3-4-3- Measured points of speed in cylinder head 69

    3-4-4- Analysis and measurement of speed using PIV method. 70

    Chapter four: Numerical simulation. 73

    4-1- Introduction. 74

    4-2- Numerical simulation of subcooled flow boiling. 74

    4-2-1- Chen method. 75

    4-2-2- BDL method. 76

    4-2-3- net forced displacement heat transfer coefficient, hfc 82

    4-2-4- nuclear boiling heat transfer coefficient, hnb 83

    4-3- one-dimensional simulation of the coolant flow in the engine cooling channel 92

    4-4- three-dimensional simulation of the coolant flow in the engine cooling channel 96

    4-4-1- Cooling flow simulation in the engine passage 96

    4-4-2- Thermal simulation of the cooling flow in the engine cooling passage 105

    Chapter five: Cooling improvement solutions. 113

    5-1- Introduction. 114

    5-2- Presenting methods to achieve uniform cooling in the engine 114

    5-2-1- The method of changing the cooling inlet and outlet pattern 114

    5-2-2- Using the flow boiling regime in order to increase the heat transfer coefficient. 119

    Sixth chapter: summary and conclusion. 129

    6-1- Summary and conclusion. 130

    6-2- Innovations 132

    6-3- Suggestions for continuing work 133

    6-4- Presented scientific products 134

    Resources and sources. 136

     

    Source:

     

    [1]       J. B. Heywood, Internal combustion engine fundamentals vol. 930: Mcgraw-hill New York, 1988.

    [2] T. L. Bergman, A. S. Lavine, F. P. Incropera, and D. P. Dewitt, "Fundamentals of heat and mass transfer," John Wiley & Sons, Inc.(March 21, 2011), 2011.

    [3] R. P. Ernest, "A Unique Cooling Approach Makes Aluminum Alloy Cylinder Heads Cost Effective," SAE Technical Paper 770832, 1977.

    [4] T. Priede and D. Anderton, "Likely advances in mechanics, cooling, vibration and noise of automotive engines," in Institution of Mechanical Engineers, Proc Part D, 1984.

    [5] C. Arcoumanis, J. Nouri, J. Whitelaw, G. Cook, and D. Foulkes, "Coolant Flow in the Cylinder Head/Block of the Ford 2.5 L DI Diesel Engine," SAE Technical Paper 841294, 1991.

    [6] P. M. Norris, W. Wepfer, K. L. Hoag, and D. Courtine-White, "Experimental and analytical studies of cylinder head cooling," SAE Technical Paper 931122, 1993.

    [7] H. Kobayashi, K. Yoshimura, and T. Hirayama, "A study on dual circuit cooling for higher compression ratio," SAE Technical Paper 841294, 1984.

    [8]       S. RouhaniRouhani, "Analysis of the separate cooling system of the block and cylinder head in the national engine," Master's thesis, Khwaja Nasiruddin Toosi University of Technology, 2013.

    [9] I. Finlay, G. Gallacher, T. Biddulph, and R. Marshall, "The application of precision cooling to the cylinder-head of a small, automotive, petrol engine," SAE Technical Paper 880263, 1988.

    [10] M. Clough, "Precision cooling of a four valve per cylinder engine," SAE Technical Paper 931123, 1993.

    [11] I. Finlay, R. Boyle, J. Pirault, and T. Biddulph, "Nucleate and film boiling of engine coolants flowing in a uniformly heated duct of small cross section," SAE Technical Paper 870032, 1987. [12] T. Hüttner and J. Hancock, "Design and Evaluation of a Low Emission Spark Ignition Engine Cylinder Head," SAE Technical Paper 960605, 1996. [13] A. Vagenas, J. Hawley, C. Brace, and M. Ward, "On-vehicle controllable cooling jets," SAE Technical Paper. 2004-01-0049, 2004.

    [14] M. Chiaberge, "New trends and developments in automotive system engineering," InTech, Turin, 2011.

    [15] J. G. Collier and J. R. Thome, Convective boiling and condensation: Oxford university press, 1994.

    [16] N. Campbell, J. Hawley, M. Leathard, R. Horrocks, and L. Wong, "Nucleate boiling investigations and the effects of surface roughness," SAE Technical Paper 1999-01-0577, 1999.

    [17] N. Campbell, D. Tilley, S. MacGregor, and L. Wong, "Incorporating nucleate boiling in a precision cooling strategy for combustion engines," SAE Technical Paper 971791, 1997. [18] K. Robinson, J. Hawley, and N. Campbell, "Experimental and modeling aspects of flow boiling heat transfer for application to internal combustion engines," Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, vol. 217, pp. 877-889, 2003. [19] T. Bo, "CFD homogeneous mixing flow modeling to simulate subcooled nucleate boiling flow," SAE Technical Paper 2004-01-1512, 2004. [20] O. Zeitoun and M. Shoukri, "Axial void fraction profile in low pressure subcooled flow boiling," International Journal of heat and mass transfer, vol. 40, pp. 869-879, 1997.

    [21]     A. Robertson, J. Hartland, and A. Gil-Martinez, "Heat Flux Estimation and the Control of Nucleate Boiling in a Laboratory Test Rig," SAE Technical Paper 2005-01-2007, 2005.

    [22]     H. Steiner, A. Kobor, and L. Gebhard, "A wall heat transfer model for subcooled boiling flow," International journal of heat and mass transfer, vol. 48, pp. 4161-4173, 2005.

    [23] H. S. Lee and A. T. O'Neill, "Comparison of boiling curves between a standard SI engine and a flow loop for a mixture of ethylene glycol and water," SAE Technical Paper 2006-01-1231, 2006.

    [24] M. Cardone, A. Senatore, D. Buono, M. Polcino, G. De Angelis, and P. Gaudino, "A Model for Application of Chen's Boiling Correlation to a Standard Engine Cooling System," SAE Technical Paper 2008-01-1817, 2008.

    [25] A. Mulemane and R. Soman, "CFD based complete engine cooling jacket development and analysis," SAE Technical Paper 2007-01-4129, 2007. [26] H. Lee, "Heat Transfer Predictions using the Chen Correlation on Subcooled Flow Boiling in a Standard IC Engine," SAE Technical Paper 2009-01-1530, 2009. [27] H. S. Lee and L. W. Cholewczynski, "A study on convection and boiling heat-transfer modes in a standard engine cooling system," SAE VTMS6, Brighton, UK, 2003. [28] H. Lee and A. O'Neill, "Forced convection and nucleate boiling on a small flat heater in a rectangular duct: Experiments with two working fluids, a 50-50 ethylene glycol—water mixture, and water," Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, vol. 223, pp. 203-219, 2009.

    [29] H. S. Lee and A. T.

Analysis and modification of EF7 engine cooling channel
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