Physics-based reduced-order modeling of flash-boiling sprays in the context of internal combustion engines

TL;DR

This paper extends a cross-sectionally averaged spray (CAS) model to simulate flash-boiling sprays in internal combustion engines, capturing key behaviors efficiently and accurately, enabling faster simulations for engine design and fuel analysis.

Contribution

The study develops a reduced-order CAS model for flash-boiling sprays that incorporates physical submodels and demonstrates significant computational speedup with accurate trend prediction.

Findings

The CAS model captures spray characteristics reasonably well across different conditions.

The model is up to 10,000 times faster than 3D CFD simulations.

It effectively predicts liquid and vapor penetration lengths in flash-boiling sprays.

Abstract

Flash-boiling injection is one of the most effective ways to accomplish improved atomization compared to the high-pressure injection strategy. The tiny droplets formed via flash-boiling lead to fast fuel-air mixing and can subsequently improve combustion performance in engines. Most of the previous studies related to the topic focused on modeling flash-boiling sprays using three-dimensional (3D) computational fluid dynamics (CFD) techniques such as direct numerical simulations (DNS), large-eddy simulations (LES), and Reynolds-averaged Navier-Stokes (RANS) simulations. However, reduced order models can have significant advantages for applications such as the design of experiments, screening novel fuel candidates, and creating digital twins, for instance, because of the lower computational cost. In this study, the previously developed cross-sectionally averaged spray (CAS) model is thus extended for use in simulations of flash-boiling sprays. The present CAS model incorporates several physical submodels in flash-boiling sprays such as those for air entrainment, drag, superheated droplet evaporation, flash-boiling induced breakup, and aerodynamic breakup models. The CAS model is then applied to different fuels to investigate macroscopic spray characteristics such as liquid and vapor penetration lengths under flash-boiling conditions. It is found that the newly developed CAS model captures the trends in global flash-boiling spray characteristics reasonably well for different operating conditions and fuels. Moreover, the CAS model is shown to be faster by up to four orders of magnitude compared with simulations of 3D flash-boiling sprays. The model can be useful for many practical applications as a reduced-order flash-boiling model to perform low-cost computational representations of higher-order complex phenomena.