Tutorial: IC Simulation for Canted Valve Engine Using Hybrid Approach

Introduction
Two approaches are employed in ANSYS FLUENT to solve in-cylinder (IC) problems, namely, hybrid approach and layering approach. The layering approach is used for engines with vertical valves like most diesel engines, while the hybrid approach is typically used for engines with canted valves like most spark ignited (SI) engines. For either approach mentioned above, IC problems solved in ANSYS FLUENT consist of three stages. 1. Decompose the geometry into dierent zones and mesh them properly. By breaking up the model into dierent zones, it is possible to apply dierent mesh motion strategies to dierent regions in a single simulation. 2. Set up the engine case in ANSYS FLUENT with the help of a setup journal. 3. Perform a transient IC simulation. In this tutorial setup and simulation process is explained for the hybrid approach. A similar tutorial, IC Simulation for Vertical Valve Engine Using Layering Approach, exists for the layering approach. This tutorial demonstrates: 1. Procedure to setup IC ow problem using journal le: The journal le automatically sets up the necessary motions for valves and piston, along with solution parameter which suit the IC simulation best. Journal le allows you to set up an IC simulation with all the best practices built-in, without learning the dynamic mesh capability. This is made possible through the correct decomposition and zone name matching. Appendix A contains a sketch of the decomposition and the corresponding zone names. 2. Procedure to solve the cold ow simulation: This tutorial makes use of a In-Cylinder Output Controls to calculate swirl and tumble ratio.

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Tutorial: IC Simulation for Canted Valve Engine Using Hybrid Approach

The limitations of the journal are: 1. The journal is applicable only for ANSYS FLUENT. 2. The journal cannot be used for 2D geometry. The journal can automatically set up the following for an IC case: 1. All necessary dynamic zones for the valve motion. 2. All necessary dynamic zones for the piston motion. 3. Boundary conditions for all interior and interface zones related to valves or piston motion but NOT inlets, outlets, symmetry, or combustion models etc. 4. All solver settings in rst order. You may need to change it to second order for greater accuracy. 5. Events to open and close valves. 6. Events to change the under-relaxation factors (URF)s. 7. Events to change the time step size. 8. Solver parameters based on experience of the engineers at ANSYS FLUENT. Note: Due to dierent le format between Windows and UNIX, if you use UNIX you may need to use dos2unix or dos2ux command to change the format for all *.scm and *.par les that come with the tutorial. You could also try to use a text editor to open the les and then save it. Otherwise, you may not be able to load the scheme le and the *.par le may not read correctly.

Prerequisites
This tutorial is written with the assumption that you have completed Tutorial 1, and that you are familiar with the ANSYS FLUENT navigation pane and menu structure. Some steps in the setup and solution procedure will not be shown explicitly.

Problem Description
This tutorial considers a 3D symmetric geometry of a IC engine cylinder conguration. Case setup is performed using a scheme le that automatically sets up necessary motions for valves and pistons along with solution parameters found to be best suit for the in-cylinder simulation.

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Figure 1: Geometry Decomposition

Setup and Solution Preparation

1. Copy the les, (IC tutorial II.msh.gz. valve.prof, R 13 IC scheme-set-4.scm, and IC-motion-parameters.par) to your working folder. 2. Use FLUENT Launcher to start the (3D) version of ANSYS FLUENT. For more information about FLUENT Launcher refer to Section 1.1.2 in the ANSYS FLUENT 13.0 Users Guide. 3. Enable Double-Precision in the Display Options list. 4. Click the Environment tab and ensure that Setup Compilation Environment for UDF is enabled. The path to the .bat le which is required to compile the UDF will be displayed as soon as you enable Setup Compilation Environment for UDF. If the Environment tab does not appear in the FLUENT Launcher dialog box by default, click the Show More Options button to view the additional settings. Note: The Display Options are enabled by default. Therefore, after you read in the mesh, it will be displayed in the embedded graphics window.

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Step 1: Mesh 1. Read the mesh le, IC tutorial II.msh.gz. File Read Mesh... As ANSYS FLUENT reads the mesh le, messages will appear in the console reporting the progress of the conversion. 2. Rotate and zoom the display to obtain the view as shown in Figure 2

Figure 2: Mesh Display

Note: The case has a symmetric plane. Use of symmetry helps reduce cell count by a factor of two and thus greatly reduce the run time. Layering is used for lower combustion chamber and the valve seat, to reduce cell count and to properly resolve the ow. Tetrahedral mesh is used in the upper combustion chamber and ports to facilitate the setup. The mesh must have the correct decomposition and names before using the journal to automatically set up the case. Figure 1 shows the geometry decomposition. In Appendix A, a sketch of the decomposition and the corresponding names are provided for quick reference.

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Step 2: General Settings 1. Check the mesh. General Check ANSYS FLUENT will perform various checks on the mesh and report the progress in the console. Make sure that the minimum volume reported is a positive number. Warnings will be displayed regarding unassigned interface zones, resulting in the failure of the mesh check. You do not need to take any action at this point, as this issue will be rectied when you dene the mesh interfaces in a later step. 2. Scale the mesh. General Scale... Retain the default settings for this tutorial,as the mesh is already scaled properly. But otherwise this is a very important step. Since the meshing parameters are determined from the initial mesh, it is imperative to properly scale the mesh. 3. Read the valve prole le. File Read Prole... (a) Select valve.prof from the Select File dialog box and click OK. This le contains valve lift information. Refer to ANSYS FLUENT Users Guide for the format of this prole. Note: The following message will appear after reading the prole. This means that two proles, i.e., ex-valve and in-valve, have been read in. The prole names will be required for the valve setup at a later stage.
Reading profiles file... 141 "ex-valve" point-profile points, angle, lift. 140 "in-valve" point-profile points, angle, lift.

4. Load the scheme le. File Read Scheme... (a) Select R 13 IC scheme-set-4.scm from the Select File dialog box and click OK. 5. IC setup. Dene User-Dened In-Cylinder Mesh Motion Setup...

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Note: The IC Setup dialog box contains some default values. You will not use these parameters as they are problem dependent. Instead, you have to read a parameter le. (a) Click Read at the bottom of the dialog box and read the input parameter le IC-motion-parameters.par. The le contains all the engine parameters and parameters required for valves motion and piston motion setup. You could also enter the parameters directly in the dialog box. Note: You can use the Write button to write out the parameter les for later use. The IC-motion-parameters.par provided was written out by this after manually entering those numbers. The parameter le is text le that can be edited easily using any text editor. The parameters are put in the le in an order that is similar to the dialog box. (b) Click OK. The journal will automatically set up mesh motion for the intake valve, exhaust valve, and piston. This automation is achieved through correct decomposition and zone name matching. If the names of the zones are incorrect, the case will not be setup and you will be notied about the zones for which the names are not matched. The scheme le will automatically select Standard k-e as the turbulence model. Note: The explanation of the parameters is in Appendix B. For this tutorial, piston type1 is used. More details on dierent type of pistons are explained in Appendix C. 6

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6. Examine the prole. See Figure 3. (a) Enter the following command to display the valve prole: /define/dynamic-mesh/controls/icp/ppl ex-valve in-valve () 0 720 10 y

Figure 3: IC Valve Prole Note: In convention with ANSYS FLUENT, the 0 crank angle (CA) is at top dead center (TDC) after compression. So, at 0 CA both intake and exhaust valves are closed as shown in Figure 3. If in your convention, 0 CA is at TDC after power stroke, you will need to shift your prole.

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Step 3: Models 1. Specify the turbulence model. Models Viscous Edit...

Journal will automatically select Standard k-epsilon turbulence model and use default values as shown in the dialog box. 2. Close the Viscous Model dialog box.

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Step 4: Zone Motion Preview Zone motion preview will translate moving zones, without solving any mesh or ow equations. This helps to quickly check valve prole and axis denition, that you put into the IC Setup dialog box. If any of them is wrong, then your zone motion will not look correct. For instance, if you use (0 0 1) as your piston motion axis (which should be (0 1 0)), then during zone motion, the piston will move in the z direction instead of y direction. 1. Set up mesh display. General Display

2. Perform a zone motion preview. Dynamic Mesh Display Zone Motion...

(a) Click Integrate. (b) Click Preview. (c) Close the Zone Motion dialog box.

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3. Write out a case le, IC tutorial II CA000.cas.gz File Write Case... The mesh is at TDC, i.e., CA 0. Step 5: Mesh Motion Preview A full 720 degree of mesh motion may not be necessary. But it is necessary to move the mesh to the simulation starting CA that is normally a few degrees before intake valve open at TDC. In this case, CA 344 is the starting point of the simulation because the intake valve opens at CA 349. 1. Perform a mesh motion preview. Dynamic Mesh Preview Mesh Motion...

(a) Enter 1396 for Number of Time Steps. This amounts to 344 degrees. Since non-constant time step size is used, 1376 = (4X344) steps of mesh motion, corresponds only to 339 degrees. (b) Enable from Options group box, Enable Autosave.

i. Enter 180 for Save Case File Every (Time Steps). ii. Click OK to close the Autosave Case During Mesh Motion Preview dialog box. Autosave helps identifying mesh motion problems if the mesh motion fails.

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You can also enable Display Mesh and Save Picture, to save the pictures of the mesh at specied Display Frequency for creating a mesh motion animation later. (c) Click Apply. (d) Click Preview. Note: Mesh motion for this tutorial case takes about one hour on serial Windows XP 3.19GHz machine. (e) Close the Mesh Motion dialog box. Step 6: Boundary Conditions Boundary Conditions 1. Specify the inlet boundary conditions. Boundary Conditions inlet Edit...

(a) Select Intensity and Hydraulic Diameter from the Specication Method drop-down list in the Turbulence group box. (b) Enter 5 % for Turbulent Intensity. (c) Enter 0.03 m for the Hydraulic Diameter. (d) Ensure that in the Thermal tab Total temperature is 300. (e) Click OK to close the Pressure Inlet dialog box. 2. Specify the outlet boundary conditions. Boundary Conditions outlet Edit...

(a) Select Intensity and Hydraulic Diameter from the Specication Method drop-down list in the Turbulence group box. (b) Enter 8 % for Backow Turbulent Intensity. (c) Enter 0.03 m for the Backow Hydraulic Diameter. (d) Ensure that in the Thermal tab Total temperature is 300. (e) Click OK to close the Pressure Outlet dialog box. 3. Make sure the boundaries with name symm-(except symmetry-bowl) have symmetry boundary condition. There is no need to specify boundary conditions for other face zones. Those will be automatically setup by the scheme. 4. Write out a case le, IC tutorial II CA344.cas.gz. File Write Case...

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Step 7: Dynamic Mesh In the In-Cylinder Output Controls dialog box, you can specify various quantities needed for the calculation of swirl and tumble along with the frequency of writing the output, to the chosen le. Swirl is used to describe circulation about the cylinder axis. Tumble ow circulates around an axis perpendicular to the cylinder axis, orthogonal to swirl ow. Dynamic Mesh 1. Click on Settings... in Options group box. 2. In the Options dialog box click In-Cylinder tab. 3. Enable Write In-Cylinder Output and click Output Controls....

(a) In the In-Cylinder Output Controls dialog box, set In-Cylinder Data Write Frequency to 1. (b) Ensure center of gravity is selected from Swirl Center Method. (c) From the Cell Zones list select uid-ch and uid-piston-layer. (d) Set X, Y, Z from Swirl Axis to 0, 0, 1 respectively. (e) Set X, Y, Z from Tumble X-Axis to 1, 0, 0 respectively. (f) Set X, Y, Z from Tumble Y-Axis to 0, 1, 0 respectively. (g) Enter ic-hybrid.txt for File Name. (h) Click OK. 12

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4. Click OK in the In-Cylinder Settings dialog box to close it. Step 8: Solution 1. Initialize the ow. Solution Initialization Initialize 2. Create a velocity magnitude contour plot. (a) Create an iso surface. Surface Iso-Surface...

i. Select Mesh... and Y-Coordinate from the list of Surface of Constant. ii. Enter 0.02 for Iso-Values. iii. Enter y=.02 for New Surface Name. iv. Click Compute and then Create. v. Close the Iso-Surface dialog box. (b) Check ID of iso surface. Surface Manage...

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In this case, it is 55. This ID will be needed later for contour plot. (c) Display iso surface. Graphics and Animations Mesh Set Up...

i. Deselect all from the list of Surfaces. ii. Select y=.02 and click Display. iii. Close the Mesh Display dialog box.

Figure 4: Iso Surface View

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(d) Specify the view. Graphics and Animations Views... i. Enter plot-view for Save Name. ii. Click Save and close the Views dialog box. (e) Display velocity magnitude contours. Graphics and Animations Contours Set Up...

i. Enable Filled in the Options group box. ii. Disable Auto Range and Clip to Range. iii. Select Velocity and Velocity Magnitude from the Contours of drop-down list. iv. Enter 0 for Min and 30 for Max. v. Select y=.02 from the Surfaces list. vi. Close the Contours dialog box. Similar velocity contour plots will be saved during the simulation. The saved plots can be used to create an animation. 3. Set up commands to save gures for animations. Calculation Activities (Execute Commands) Create/Edit...

(a) Set Dened Commands to 1. (b) Enable Active. (c) Set Every to 20. (d) Select Time-Step from the drop-down list of When. (e) Enter /dis/sw 1 /dis/set/cont/sur (y=.02) /dis/view/rv plot-view /dis/cont vm 0 30 /dis/sp/vel %t.tiff for Command.

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(f) Click OK. Note: In the above command instead of y=.02, the surface ID for surface y=.02 can be used. The ID for this surface is 55. This can be dierent on dierent systems. You could create other contour plots using similar steps. 4. Set the time step parameters for calculations. Calculation Activities (a) Enter 180 for Autosave Every (Time Steps). (b) Click Edit.... i. Enter ./IC tutorial II CA344.gz for File Name. ii. Click OK to close the Autosave dialog box. In the Autosave dialog box, IC tutorial II CA344 .gz is used as the lename. The number of time steps will be appended to it. So, at time step 180, a case/data, IC tutorial II CA344 0180.cas/dat.gz will be automatically saved. Note: If greater accuracy is desired, change to Second Order Upwind discretization Solution Methods 5. Write out a case and data le, IC tutorial II CA344 0000.cas.gz File Write Case & Data... 6. Run the simulation for the 1440 time steps. This will complete half cycle of the cylinder. If you require, you can run for 2880 time steps to observe the full cycle. Run Calculation Step 9: Postprocessing At the end of the simulation you will have the following les: 1. Ti les for velocity magnitude. 2. Auto-saved case and data les. 3. A text le ic-hybrid.txt,containing swirl, x-tumble, y-tumble, and moment of inertia as a function of CA. For more information refer to section 11.6.3 In-Cylinder Settings, in the ANSYS FLUENT Users Guide.

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Figure 5: CA = 379(deg)

Figure 5: CA = 424 (deg)

Figure 5: CA = 469(deg)

Figure 5: CA = 514 (deg)

Figure 5: CA = 559(deg)

Figure 5: CA = 599 (deg)

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Figure 6: CA = 644 (deg)

Figure 6: CA = 689 (deg)

Summary
In this tutorial you have learned how to setup an IC engine cold ow case in ANSYS FLUENT. Scheme le provided with this tutorial can be used for setting up case on any other IC engine geometry, provided mesh and name of boundary and cell zones are created as per specication in the Appendix A.

Appendix A

Figure 7: Sketch of Decomposition and Zone Names

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No. 1 2 3 4 5

Fluid Zone Name fluid-ch fluid-rootname-ib fluid-rootname-port fluid-rootname-vlayer fluid-piston-layer

Mesh Requirement tet mesh layered mesh any mesh layered mesh layered mesh

Figure 8: Boundary Zones

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No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Boundary Zone Name intf-int-rootname-ib-uid-ib intf-int-rootname-ib-uid-port intf-int-rootname-ob-uid-vlayer intf-int-rootname-ob-uid-port intf-rootname-ib-uid-ib intf-rootname-ib-uid-ob-quad intf-rootname-ib-uid-ob-tri intf-rootname-ob-uid-ch intf-rootname-ob-uid-vlayer seat-rootname rootname-ch rootname-ib rootname-ob int-piston cyl-tri piston

Appendix B
Parameters in the IC Setup dialog box. 1. Input parameters under Engine Parameters tab: Crank Shaft Speed: Engine RPM. Crank Angle Step Size: Time step size in terms of CA. Piston stroke: Piston Stroke and Connecting Rod Length, together control the piston motion. Connecting Rod Length: Piston Stroke and Connecting Rod Length, together control the piston motion. Minimum Valve Lift: Closest gap from valve and valve seat. Symmetry Engine: Use this option if one has a symmetry engine like the demo. Point on Symmetry: Point on Symmetry and Symmetry Normal together dene a plane for nodes projection. Symmetry Normal: Point on Symmetry and Symmetry Normal together dene a plane for nodes projection. Cylinder axis origin and cylinder axis direction together dene a cylinder for the engine cylinder. ANSYS FLUENT needs this to project nodes on the engine cylinder back to a perfect cylinder. 2. Input Parameters under Piston Motion Setup tab: Meshing Strategy Hybrid Approach: This approach is used for canted valve engine. Three dierent piston mesh types can be modeled under Hybrid Approach. 20

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Layering Approach: This approach is used for the vertical valve engine. There are two mesh types (conformal and non-conformal mesh type) used for layering approach. For further details please refer IC tutorial I-B. Piston Type: There are three piston types. For pistons with enough room to put one layer to start with, select 1. For at pistons with tight squish combustion chamber and thus insert-boundary-layer is used, select 2. For complex piston shape like GDI engines and thus insert-interior-layer is used, select 3. The decomposition for dierent piston types is dierent. Appendix C explains dierence between these piston types. Piston Stroke Cuto: Parameter used to control the height of upper remeshing combustion chamber. The rule of thumb is to use max valve lift plus 4 or 5mm. Cylinder Radius: Cylinder radius. Cylinder Axis Direction: Cylinder Axis Origin and Cylinder Axis Direction together dene a cylinder for the engine cylinder. ANSYS FLUENT needs this to project nodes on the engine cylinder back to a perfect cylinder. Cylinder Axis Origin: Cylinder Axis Origin and Cylinder Axis Direction together dene a cylinder for the engine cylinder. ANSYS FLUENT needs this to project nodes on the engine cylinder back to a perfect cylinder. 3. Input parameters under Valve Motion Setup tab: Number of Valves: The total number of vales in the engine. Valve Number: Valve number for which parameters are setup. For example, if there are total 4 valves, valve number parameter will vary from 1 to 4. The parameters like Valve Name, Valve Prole Name, etc., are required to setup for each valve number and these parameters are stored against the valve number. Valve Name: The auto set up is done through name matching system. This is the valve root name. Valve Prole Name: Valve prole is used to dene valve motion. This name is shown up on ANSYS FLUENT screen during the step of Read the Valve Prole. Open Valve: CA to open the valve. At the specied CA, the valve will open by forming the non-conformal interface. Close Valve: CA to close the valve. At the specied CA, the valve will close by deleting the non-conformal interface. Refer Appendix D for the recommended practice to select the opening and closing crank angles. Valve Margin Radius: Valve radius. Valve Axis Direction: Valve Axis Origin and Valve Axis Direction together dene a cylinder for the valve. ANSYS FLUENT needs this to project nodes back to a perfect cylinder. Valve Axis Origin: Valve Axis Origin and Valve Axis Direction together dene a cylinder for the valve. ANSYS FLUENT needs this to project nodes back to a perfect cylinder. 21

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Variable URFs: With this option enabled, the URFs are not a constant. When valves are opening or closing, the URFs for k, e, Momentum, and Pressure will be automatically reduced and later on switched back. Variable Crank Angle Step Size: With this option enabled, the time step size is not a constant. When valves are opening or closing, the time step size will be automatically reduced and later on switched back. Duration: The duration for reduced URFs or/and time step size.

Appendix C
Dierent types of piston and treatment Piston shape can vary from at piston seen in some spark ignited (SI) engines to very complex piston bowl shape seen in some diesel or GDI engines. This physical dierence makes it necessary to treat dierent pistons in dierent ways. In ANSYS FLUENT all dierent pistons can be categorized into three dierent types. 1. Piston type 1 is designated for engines with enough squish volume to put one layer of wedge elements when the piston is at the TDC, be it a at piston or piston with a bowl, as shown in Figure 9. The gure also shows the names required. Note that for the geometry with a bowl, piston should also include the bowl.

Figure 9: Piston Type 1 Decomposition and Zone Names

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The mesh requirement is shown in Figure 10. A layer of wedge elements is needed for layering for piston type 1. In most cases, you can not put a layer of hex mesh because the squish volume in typical engines would not allow for extra pyramids on top of int-piston needed to make the transition from hex mesh to tet mesh. If your engine has large squish volume to allow for pyramids and thus using hex vs. wedges, contact your support engineer.

Figure 10: Piston Type 1 Mesh Requirement

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2. Piston type 2 is designated for engines without enough squish volume to put one layer of wedge elements when the piston is at TDC, be it a at piston or piston with a bowl, as shown in Figure 11. The gure also shows the names required.

Figure 11: Piston Type 2 Decomposition and Zone Names

The mesh requirement is shown in Figure 12. With piston type 2 you have the choice to include a bowl. This option is in the IC Setup dialog box. For piston type 2, a layer of wedge elements is not needed. Instead, ANSYS FLUENT will automatically create a layer at specied CA. The two CAs for Intake Stroke and Power Stroke are specied in the IC Setup dialog box.

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Figure 12: Piston Type 2 Mesh Requirement

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Piston type 1 and 2 do not allow the valves to penetrate into the bowl because the valves will interfere with either int-piston for piston type 1 or piston for piston type 2. 3. Piston type 3 is designated for engines with such valve penetration. Figure 13 shows the names required.

Figure 13: Piston Type 3 Decomposition and Zone Names

The mesh requirement is shown in Figure 14.

Figure 14: Piston Type 3 Mesh Requirement

For piston type 3, a layer of wedge elements is not needed. Instead, ANSYS FLUENT will automatically create a layer at user specied CA in the IC Setup dialog box. There is only one insert CA for piston type 3. The same angle is used for both power stroke and intake stroke. Insert location uses Cylinder Axis Origin.

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Piston type 1 and 2 are commonly used for diesel and gasoline engines. Piston type 3 could be used for some GDI engines with deep valve penetration. Piston type 3 is the most general and requires less decomposition. However, it has less number of layered elements and utilizes more tet cells and thus typically has more cells and takes more computational time. If possible, you should always try to use piston type 1 or 2. The mesh les for all the above piston types are provided with this tutorial. You will need to do the following to see the results. 1. Read the mesh le and the prole. 2. Load the scheme le. 3. Read the parameter le in through the IC Setup dialog box. This will set up the piston. Make the required changes in the Piston Motion Setup. 4. Perform Steps 3 through Step 9 of this tutorial.

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Appendix D
Determining the valve opening and closing angles In Valve Motion Setup in IC Setup dialog box, you need to specify the opening and closing CA of each valve. It should be specied in such a way that the ow to the chamber should neither be under predicted nor over predicted. If we specify the actual valve opening CA in the setup this will allow too much of ow into the chamber as there is a minimum lift for the valve due to the V-layer modeled in the geometry decomposition. To overcome this, one can adopt the following approach in setting up the valve parameters. Typical valve prole will be as shown below. As per prole valve opens at 350 deg CA and at about 358 deg CA the valve lift reaches 0.1 mm ((in-valve point 140 1) (angle 3.500000e+02 3.515000e+02 3.530000e+02 3.545000e+02 3.560000e+02 3.5750000e+02 ..............) (lift 1.000000e-07 1.130000e-06 3.848000e-05 5.565000e-05 1.010000e-04 1.090000e-04 ................) ) While modeling, IC case in ANSYS FLUENT we usually keep the V-layer thickness to 0.1mm.

Figure 15: Valve Motion in Actual Engine and Simulation

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If valve opens at 350 deg CA, as per prole and in practice ow will vary according to the lift prole in Figure 16.

Figure 16: Actual Valve Opening Prole

If the valve opening CA is set as 350 degrees in ANSYS FLUENT the simulated valve lift prole will be as shown in Figure 17 and the ow will be over predicted.

Figure 17: Valve Opened at CA 350 in ANSYS FLUENT

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If the valve opening CA is set as 356 in ANSYS FLUENT the simulated valve lift prole will be as shown in Figure 18 and the ow will be under predicted.

Figure 18: Valve Opened at CA 356 in ANSYS FLUENT

So the recommended practice is to keep the valve opening CA at the average of both the above which is CA 353. The simulated valve lift prole is as shown in Figure 19 and this will provide the ow rate approximately equal to the actual ow rate.

Figure 19: Valve Opened at CA 353 in ANSYS FLUENT

The same approach is used in determining valve closing CA.

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