Analysis and evaluation of the thermal shock phenomena in the in-cylinder surfaces of a DI diesel engine during its transient operation

Abstract

This paper presents the results from the analysis of an experimental investigation with the aim of providing an insight into the cyclic thermal shock phenomena occurring in the internal cylinder wall surfaces of a direct injection (DI), air-cooled diesel engine during the initial stage of a transient operation. The mechanism of cyclic heat transfer is investigated during engine transient events, viz. after a sudden change in engine speed and/or load. The experimental installation allowed both long- and short-term signal types to be recorded on a common time reference base during the transient event. Processing of experimental data was accomplished using a modified version of one-dimensional heat conduction theory with Fourier analysis, capable of catering for the special characteristics of transient engine operation. Based on this model, the evolution of local surface heat flux during a transient event was calculated. Two engine transient events are examined, which present a key difference in the way the load and speed changes are imposed on each one. During the analysis of experimental results the most important parameters characterizing thermal shock, such as the heat wave velocity and length of penetration, are quantified for each event, providing a comprehensive insight into the causes and consequences of this dangerous phenomenon. The results, in addition, confirm the theoretical predictions for the development of the thermal field during an engine transient event, as presented by the authors in previous work. Each thermal transient event is characterized by two distinct phases, that is the ‘thermodynamic’ and the ‘structural’ one, which are appropriately configured and analysed. From the results it is revealed that in the case of a severe variation, in the first 20 cycles after the beginning of the transient event, the wall surface temperature and heat flux amplitude on the cylinder head was almost three times higher than that observed in the ‘normal’ temperature oscillations occurring during steady-state operation.

Keywords

heat transfer unsteady diesel engine transient operation thermal shock

Get full access to this article

View all access options for this article.

References

Benson

R. S.

Whitehouse

N. D.

Internal combustion engines, 1979 (Pergamon Press, Oxford).

Heywood

J. B.

Internal combustion engine fundamentals, 1988 (McGraw-Hill, New York).

Ferguson

C. R.

Internal combustion engines, 1986 (John Wiley, New York).

Annand

W. J. D.

Heat transfer in the cylinders of reciprocating internal combustion engines. Proc. Instn Mech. Engrs, 1963, 177, 973–990.

Borman

Nishiwaki

Internal-combustion engine heat transfer. Prog. Energy Combust. Sci., 1987, 13, 1–46.

Assanis

D. N.

Heywood

J. B.

Development and use of a computer simulation of the turbocompounded diesel engine performance and component heat transfer studies. SAE paper 860329, 1986.

Rakopoulos

C. D.

Rakopoulos

D. C.

Giakoumis

E. G.

Kyritsis

D. C.

Validation and sensitivity analysis of a two-zone diesel engine model for combustion and emissions prediction. Energy Conversion Mgmt, 2004, 45, 1471–1495.

Rakopoulos

C. D.

Rakopoulos

D. C.

Kyritsis

D. C.

Development and validation of a comprehensive two-zone model for combustion and emissions formation in a DI diesel engine. Int. J. Energy Res., 2003, 27, 1221–1249.

Rakopoulos

C. D.

Antonopoulos

K. A.

Rakopoulos

D. C.

Hountalas

D. T.

Multi-zone modeling of combustion and emissions formation in DI diesel engine operating on ethanol-diesel fuel blends. Energy Conversion Mgmt, 2008, 49, 625–643.

10.

Rakopoulos

D. C.

Rakopoulos

C. D.

Giakoumis

E. G.

Papagiannakis

R. G.

Kyritsis

D. C.

Experimental-stochastic investigation of the combustion cyclic variability in HSDI diesel engine using ethanol-diesel fuel blends. Fuel, 2008, 87, 1478–1491.

11.

Rakopoulos

C. D.

Antonopoulos

K. A.

Rakopoulos

D. C.

Development and application of multi-zone model for combustion and pollutants formation in direct injection diesel engine running with vegetable oil or its bio-diesel. Energy Conversion Mgmt, 2007, 48, 1881–1901.

12.

Rakopoulos

C. D.

Giakoumis

E. G.

Sensitivity analysis of transient diesel engine simulation. Proc. IMechE, Part D: J. Automobile Engineering, 2006, 220, 89–101.

13.

Morel

Wahiduzzaman

Fort

E. F.

Heat transfer experiments in an insulated diesel. SAE paper 880186, 1988.

14.

Enomoto

Furuhama

A study of the local heat transfer coefficient on the combustion chamber walls of a four-stroke gasoline engine. Bull. JSME, 1989, 32, 107–114.

15.

Kamo

Bryzik

Cummins/TACOM advanced adiabatic engine. SAE paper 840428, 1984.

16.

Assanis

D. N.

Effect of combustion chamber insulation on the performance of a low heat rejection diesel engine with exhaust heat recovery. Heat Recov. Syst. CHP, 1989, 9, 475–484.

17.

Rakopoulos

C. D.

Antonopoulos

K. A.

Rakopoulos

D. C.

Giakoumis

E. G.

Investigation of the temperature oscillations in the cylinder walls of a diesel engine with special reference to the limited cooled case. Int. J. Energy Res., 2004, 28, 977–1002.

18.

Perez-Blanco

Experimental characterization of mass, work and heat flows in an air cooled, single cylinder engine. Energy Conversion Mgmt, 2004, 45, 157–169.

19.

Chen

Hsieh

Heat transfer model for scooter engines. SAE paper 2008-01-0387, 2008.

20.

Nakashima

Toda

Ishihara

Yamamoto

Optimizing the cooling effect of fins with slits on an air-cooled cylinder by increasing natural convection. SAE paper 2008-01-1170, 2008.

21.

Chang

Filipi

Assanis

D. N.

Kuo

T.-W.

Najt

Rask

Characterizing the thermal sensitivity of a gasoline homogeneous charge compression ignition engine with measurements of instantaneous wall temperature and heat flux. Int. J. Engine Res., 2005, 6, 289–309.

22.

Chang

Güralp

Filipi

Assanis

D. N.

Kuo

T.-W.

Najt

Rask

New heat transfer correlation for an HCCI engine derived from measurements of instantaneous surface heat flux. SAE paper 2004-01-2996, 2004.

23.

Demuynck

Raes

Zuliani

De Paepe

Sierens

Verhelst

Local heat flux measurements in a hydrogen and methane spark ignition engine with a thermopile sensor. Int. J. Hydrogen Energy, 2009, 34, 9857–9868.

24.

Demuynck

Pauwels

Verhelst

De Paepe

Sierens

Experimental research on the heat transfer inside a hydrogen combustion engine: evaluation and construction of measurement methods. In Proceedings of the FISITA 2008 World Automotive Congress, Student Congress, Munich, Germany 14–19 September 2008, paper no. F2008-SC-037.

25.

Farrugia

Alkidas

A. C.

Sangeorzan

B. P.

Cycle-averaged heat flux measurements in a straight-pipe extension of the exhaust port of a SI engine. Trans. SAE, J. Engines, 2006, 115, 565–575; SAE paper 2006-01-1033, 2006.

26.

Sammut

Alkidas

A. C.

Relative contributions of intake and exhaust tuning on SI engine breathing – a computational study. SAE paper 2007-01-0492, 2007.

27.

Balzan

Sangeorzan

Alkidas

A. C.

Steady-state local heat flux measurements in a straight pipe extension of an exhaust port of a spark ignition engine. SAE paper 2007-01-3990, 2007.

28.

Ranganathan

R. P.

Turner

D. W.

Franchett

M. E.

Exhaust manifold gas temperature predictions using system level data driven modelling. SAE paper 2005-01-0698, 2005.

29.

Alkidas

A. C.

Myers

J. P.

Transient heat-flux measurements in the combustion chamber of a spark-ignition engine. Trans. ASME, J. Heat Transfer, 1982, 104, 62–67.

30.

Alkidas

A. C.

Cole

R. M.

Transient heat-flux measurements in a divided-chamber diesel engine. Trans. ASME, J. Heat Transfer, 1985, 107, 439–444.

31.

Rakopoulos

C. D.

Hountalas

D. T.

Mavropoulos

G. C.

Giakoumis

E. G.

An integrated transient analysis simulation model applied in thermal loading calculations of an air-cooled diesel engine under variable speed and load conditions. Trans. SAE, J. Engines, 1997, 106, 923–939; SAE paper 970634, 1997.

32.

Liu

Jiang

Dong

Liu

3-D Numerical simulation of transient heat transfer among multi-component coupling system in internal combustion chamber. SAE paper 2008-01-1818, 2008.

33.

Mure

C. R.

Rhee

K. T.

Instantaneous heat transfer over the piston of a motored direct injection-type diesel engine. SAE paper 890469, 1989.

34.

Serrano

J. R.

Galindo

Bermúdez

Lópezr

J. J.

Cycle-to-cycle diesel combustion characterization during engine transient operation. SAE paper 2001-01-3262, 2001.

35.

Rakopoulos

C. D.

Mavropoulos

G. C.

Study of the steady and transient temperature field and heat flow in the combustion chamber components of a medium speed diesel engine using finite element analyses. Int. J. Energy Res., 1996, 20, 437–464.

36.

Rakopoulos

C. D.

Mavropoulos

G. C.

Experimental instantaneous heat fluxes in the cylinder head and exhaust manifold of an air-cooled diesel engine. Energy Conversion Mgmt, 2000, 41, 1265–1281.

37.

Rakopoulos

C. D.

Mavropoulos

G. C.

Effects of transient diesel engine operation on its cyclic heat transfer: an experimental assessment. Proc. IMechE, Part D: J. Automobile Engineering, 2009, 223, 1373–1394.

38.

Mavropoulos

G. C.

Experimental study of the interactions between long and short-term unsteady heat transfer responses on the in-cylinder and exhaust manifold diesel engine surfaces. Appl. Energy, 2010. DOI: 10.1016/j.apenergy.2010.09.018.

39.

Cho

K.-W.

Assanis

Filipi

Szekely

Najt

Rask

Experimental investigation of combustion and heat transfer in a direct-injection spark ignition engine via instantaneous combustion chamber surface temperature measurements. Proc. IMechE, Part D: J. Automobile Engineering, 2008, 222, 2219–2233.

40.

Bohac

S. V.

Baker

D. M.

Assanis

D. N.

A global model for steady state and transient S.I. engine heat transfer studies. SAE paper 960073, 1996.

41.

Lin

C. S.

Foster

D. E.

An analysis of ignition delay, heat transfer and combustion during dynamic load changes in a diesel engine. SAE paper 892054, 1989.

42.

Assanis

D. N.

Filipi

Z. S.

Fiveland

S. B.

Syrimis

A methodology for cycle-by-cycle transient heat release analysis in a turbocharged direct injection diesel engine. SAE paper 2000-01-1185, 2000.

43.

Wang

Stone

C. R.

A study of combustion, instantaneous heat transfer, and emissions in a spark ignition engine during warm-up. Proc. IMechE, Part D: J. Automobile Engineering, 2008, 222, 607–618.

44.

Rakopoulos

C. D.

Giakoumis

E. G.

Rakopoulos

D. C.

Study of the short-term cylinder wall temperature oscillations during transient operation of a turbocharged diesel engine with various insulation schemes. Int. J. Engine Res., 2008, 9, 177–193.

45.

Rakopoulos

C. D.

Mavropoulos

G. C.

Hountalas

D. T.

Modeling the structural thermal response of an air-cooled diesel engine under transient operation including a detailed thermodynamic description of boundary conditions. SAE paper 981024, 1998.

46.

Rakopoulos

C. D.

Mavropoulos

G. C.

Components heat transfer studies in a low heat rejection DI diesel engine using a hybrid thermostructural finite element model. Appl. Thermal Engng, 1998, 18, 301–316.

47.

Rakopoulos

C. D.

Rakopoulos

D. C.

Mavropoulos

G. C.

Giakoumis

E. G.

Experimental and theoretical study of the short term response temperature transients in the cylinder walls of a diesel engine at various operating conditions. Appl. Thermal Engng, 2004, 24, 679–702.

48.

Rakopoulos

C. D.

Mavropoulos

G. C.

Experimental evaluation of local instantaneous heat transfer characteristics in the combustion chamber of air-cooled direct injection diesel engine. Energy, 2008, 33, 1084–1099.

49.

Mavropoulos

G. C.

Rakopoulos

C. D.

Hountalas

D. T.

Experimental assessment of instantaneous heat transfer in the combustion chamber and exhaust manifold walls of air-cooled direct injection diesel engine. SAE Int. J. Engines, 2008, 1(1), 888–912; SAE paper 2008-01-1326, 2008.

50.

Mavropoulos

G. C.

Rakopoulos

C. D.

Hountalas

D. T.

Experimental investigation of instantaneous cyclic heat transfer in the combustion chamber and exhaust manifold of a DI diesel engine under transient operating conditions. SAE paper 2009-01-1122, 2009.

51.

Keribar

Morel

Thermal shock calculations in I.C. engines. SAE paper 870162, 1987.

52.

Zhang

Wang

Hong

Han

Modification and validation of the thermal shock parameter for ceramic matrix composites under water quenching condition. Mater. Des., 2009, 30, 4552–4556.

53.

Lam

Thermal propagation in solids due to surface laser pulsation and oscillation. Int. J. Thermal Sci, 2010, 49, 1639–1648.

54.

Morel

Keribar

Blumberg

Cyclical thermal phenomena in engine combustion chamber surfaces. SAE paper 850360, 1985.

55.

Beck

B. T.

Demonstrations of transient conduction heat flux phenomena for the engineering laboratory. In Proceedings of the 32nd ASEE/IEEE Conference on Frontiers in education, Boston, MA, 6–9 November 2002, pp. 1–6.

56.

Welty

J. R.

Engineering heat transfer, 1974 (John Wiley, New York).

57.

Tzou

D. Y.

An engineering assessment to the relaxation time in thermal wave propagation. Int. J. Heat Mass Transfer, 1993, 36, 1845–1851.

58.

Temperature measurement handbook, vol. VIII, 1997 (NANMAC, Framingham, MA).

59.

Rakopoulos

C. D.

Mavropoulos

G. C.

Modelling the transient heat transfer in the ceramic combustion chamber walls of a low heat rejection diesel engine. Int. J. Veh. Des., 1999, 22, 195–215.

60.

Rakopoulos

C. D.

Giakoumis

E. G.

Diesel engine transient operation – principles of operation and simulation analysis, 2009 (Springer, London).