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SAE TECHNICALPAPER SERIES 2001-01-0547
Diesel Engine Combustion Chamber Geometry
Optimization Using Genetic Algorithms
and Multi-Dimensional Spray
and Combustion Modeling
D. D. Wickman, P. K. Senecal and R. D. ReitzEngine Research Center, University of Wisconsin-Madison
Reprinted From: Advances in Combustion 2001(SP1574)
SAE 2001 World CongressDetroit, Michigan
March 5-8, 2001
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2001-01-0547
Diesel Engine Combustion Chamber GeometryOptimization Using Genetic Algorithms and Multi-
Dimensional Spray and Combustion Modeling
D. D. Wickman, P. K. Senecal, and R. D. ReitzEngine Research Center, University of Wisconsin-Madison
Copyright 2001 Society of Automotive Engineers, Inc
ABSTRACT
The recently developed KIVA-GA computer code wasused in the current study to optimize the combustionchamber geometry of a heavy-duty diesel truck engine
and a high-speed direct-injection (HSDI) small-borediesel engine. KIVA-GA performs engine simulationswithin the framework of a genetic algorithm (GA) global
optimization code. Design fitness was determined usinga modified version of the KIVA-3V code, whichcalculates the spray, combustion, and emissions
formation processes. The measure of design fitnessincludes NOx, unburned HC, and soot emissions, as wellas fuel consumption. The simultaneous minimization of
these factors was the ultimate goal.The KIVA-GA methodology was used to
optimize the engine performance using nine input
variables simultaneously. Three chamber geometryrelated variables were used along with six othervariables, which were thought to have significant
interaction with the chamber geometry. The inputvariables include the piston bowl radius, the piston bowldepth, the piston crown height, the start of injection
(SOI) timing, the percent of cooled exhaust gasrecirculation (EGR), the swirl ratio (SR) at intake valveclosure (IVC), the duration of injection (DOI), the fuel
injection nozzle hole size, and the angle of a fuel
injection plume with respect to the cylinder axis. Bothengines were optimized at a medium-speed, high-load
condition with a similar global equivalence ratio. Theresults show impressive reductions in both exhaustemissions and fuel consumption.
INTRODUCTION
Recently, much research effort and resources havefocused on promising new alternatives to interna
combustion (IC) engines (e.g., fuel cells). Theseadvanced concepts have potential as clean and efficientpowerplants of the future. However, in the much nearer
future, advances in combustion will lead to cleaner andmore efficient engines using practical fuels. It is theauthors opinion that there is significant room fo
improvement remaining with IC engines. The currenwork showcases a newly developed optimization tool forexploring the vast design space being opened up by
modern flexible electronically controlled engines.It is well known that the spray characteristics
must be well matched with the combustion chambe
geometry and air motion to achieve optimal performancein a direct injection (DI) diesel engine. Singal et al. [1]provide a review of the spray-air motion interaction in DI
diesels. The improvement of the chamber geometry hasbeen the focus of many previous studies. In the presentpaper, a brief review of modern DI diesel chamber
designs is given, followed by a review of previousexperimental and computational studies on the effect ofchamber geometry. The focus of this paper is the
optimization of the engine chamber geometry usingcomputer modeling techniques.
BACKGROUND
Most modern DI diesel designs can be categorized as
either an open chamber or a re-entrant chamber design.Most small-bore diesel engines use a small diameter,relatively deep, re-entrant type bowl. The fuel spray is
typically aimed at the bowl lip. This design has beenused for its high swirl and strong squish flows, which
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tend to promote sufficient mixing, especially at highengine speeds. Some researchers have found that
when modern high-pressure injection systems are usedalong with sufficiently small bowl throat diameterchambers, liquid impingement occurs on the piston at
certain operating conditions. They contend that thetraditional small diameter bowl may be inappropriatewhen used with modern high-pressure injection systems.
Larger heavy-duty engines have typically usedlarger diameter, open-type bowls. These systems relymore on the fuel spray than the air motion to provide the
mixing energy required. These engines generallyoperate at lower speeds, where the mixing rate requiredfor complete combustion is lower. The orientation of the
fuel spray varies from engine to engine. Some aim thefuel spray along the bottom surface of the bowl, othersdirect the fuel towards the squish region.
Middlemiss [2] performed an extensiveexperimental study on the effect of chamber geometry ina small-bore high-speed diesel engine. Many different
designs were tried. The designs included a baseline,open-type chamber with a small center crown and a hostof re-entrant designs, where the throat diameter and
angle of the re-entrant portion of the bowl were varied.One of the re-entrant designs included a center crown.Four bowl lip designs were tried along with a variety of
compression ratios in a parametric study. In general, itwas found that re-entrant chambers resulted in highermixing rates thereby allowing retarded injection timings
and higher speed operation. This resulted in low sootand NOx emissions with no degradation in fueleconomy.
Saito et al. [3] performed an experimental study
of bowl geometry in a small-bore diesel engine. Twoopen-type chambers were tried, one shallow and one
deep. A re-entrant chamber was also tried, with equalmaximum bowl diameter to the open chambers. Thethroat diameter of the re-entrant bowls was varied. It
was found that a 40 mm throat diameter was optimal.They found that the re-entrant chamber producedshorter ignition delays, lower fuel consumption, and
lower soot and NOx emissions when used with retardedinjection timings.
Sakata et al. [4] performed a combined
experimental and computational study of piston bowldesign in a small-bore diesel engine. They found that a
specially designed bump (so-called reflex edge) on there-entrant portion of the bowl increased fuel spray airentrainment and mixing. This resulted in increasedperformance and reduced hydrocarbon (HC) emissions.
An experimental study of the effects of the sprayorientation, injector hole size and number, compressionratio, and combustion chamber geometry was carried
out by Corcione et al. [5]. They used a small-bore air-cooled DI diesel. Two bowl shapes were tried, a parallelsided open chamber (so-called toroidal) and a re-entrant
chamber. In general, it was found that the toroidachamber performed better at low engine speeds and the
re-entrant bowl was better at high speeds.Zhang et al. [6] performed an experimental study
on the effect of chamber geometries on combustion
behavior. Three geometries were investigated, a right-circular-cylinder dish type open bowl, a flat bottom reentrant bowl, and the re-entrant bowl with a pronounced
center crown. They concluded that the re-entrant bowwith the center crown resulted in the fastest combustionThey also found it was important to achieve a good
fuel/flame distribution inside and outside the bowl toreduce soot emissions.
Zolver et al. [7] performed a computational study
on piston bowl shapes in a small-bore diesel engine.Injection characteristics were found to have a firstorder control of the combustion process, followed by the
piston bowl shape. It was found that the intake stroke isimportant to generate a good mean velocity pattern atBDC, both in terms of its magnitude and structure. For a
given internal geometry, the flow field controls theturbulence and its dissipation rate at the end ofcompression. The bowl design and volume balance
(between the bowl and squish regions) were found toplay an important role in defining the flow near TDC.Raising the swirl level and turbulence or destroying swirl
to create turbulence were found to be productiveapproaches. NOx emissions were reduced throughchamber-geometry-generated turbulence. An interesting
configuration with individual pockets for each sprayplume was investigated, with favorable results.
De Risi et al. [8] performed a combined
experimental and computational study on the effects of
chamber geometry and engine speed on emissions in asmall-bore diesel. The basic chamber shape
investigated was a Mexican hat-type bowl. Five differenvariations of this shape were tried, one of which was anopen-type bowl. They also tried a bowl with a reflex
edge, similar to that of Sakata et al. [4]. They found theeffect of bowl geometry more prevalent at low enginespeeds. At higher engine speeds a smoother bowl lip
resulted in lower soot and higher NOx. The highly reentrant bowl was found to have performance moreindependent of engine speed, however the spray angle
and injection timing became more critical. The besresults were found when aiming the fuel spray at the
bottom of the bowl.Bianchi et al. [9] performed a computationastudy on the use of a larger diameter, less re-entrantbowl configuration along with high pressure common rail
fuel injection and low swirl in a small-bore diesel engineThe concept was to use a bowl design more well suitedto the modern injection system, thereby eliminating
spray-wall impingement and the need for high swirlThis would increase the volumetric efficiency andpossibly allow for simultaneous reductions in exhaus
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emissions and fuel consumption. The spray angle andnumber of injector holes was also changed. It was found
that the high-pressure common rail injection systemprovided sufficient mixing without a highly re-entrantbowl and high swirl. They were able to reduce soot and
NOx emissions, while paying only a small indicatedmean effective pressure (imep) penalty.
Boulouchos [10] outlined possible future
strategies for combustion, which included homogeneouscharge external ignition (HCEI), stratified charge externalignition (SCEI), stratified charge compression ignition
(SCCI), and homogeneous charge compression ignition(HCCI). The present paper focuses on the optimizationof traditional diesel combustion (so-called SCCI).
Ultimately, clean and efficient SCCI combustion may beachieved when operation takes place within the elusivewindow described by Boulouchos [10], where mixing
takes place fast enough to avoid stagnant soot-producing fuel rich zones and hot burned gases arequenched to global temperatures on time scales shorter
than those required for significant NOx production.
SCOPE OF PRESENT STUDY
The current work demonstrates the use of the newlydeveloped design methodology of Senecal and Reitz
[11, 12] (KIVA-GA). KIVA-GA performs enginesimulations (using the KIVA code) within the frameworkof a genetic algorithm (GA) global optimization code.
Genetic algorithms can be used as an efficient methodof optimization in a large search space. Senecal andReitz successfully demonstrated the use of a GA in
optimization of a heavy-duty diesel engine with split
injection capability. In their study, boost, % EGR,injection duration, injection timing, % mass in the first
injection pulse, and the dwell between injection pulseswere allowed to vary within a predefined range. Theresults showed soot emissions at half the baseline level,
NOx emissions at one-third of the baseline, and a 15%reduction in fuel consumption.
The goal of the current study is the same as that
of the work of Senecal and Reitz [11, 12] i.e., thereduction of emissions and fuel consumption, subject tocertain predefined constraints. However, the parameters
varied are different. In total 9parameters were used, 3geometric and 6 other parameters with significant
interaction. The 3 parameters related to chambergeometry are the bowl diameter, the bowl depth (as a %of the maximum bowl depth), and the central crownheight of the piston (as a % of the bowl depth).
Chamber geometry optimization seems to be anexcellent application for KIVA-GA, since an extensiveexperimental study would require many different pistons
to be manufactured. In this study, only open-typeMexican hat shaped chambers were considered.
Figure 1 shows examples of possible chambeshapes within the search space and the three geometric
parameters varied. Grid generation was automatedusing the program PKSgrid. The squish height isadjusted automatically in each case to preserve the
compression ratio. The 6 other parameters are theinjection duration, the injector hole size (as a % of themaximum hole size), the injection angle (with respect to
the cylinder axis), the start of injection timing (SOI), theswirl ratio (SR), and the % of cooled exhaust gasrecirculated (EGR). Table 1 lists these parameters, the
ranges through which they were allowed to vary, and theresolution of each parameter (# of steps allowed withineach parameter). Using these parameters and
resolutions results in a search space containing about7x10
10possible designs. The hole size is given as % of
maximum hole size, which is a function of injection
duration, such that the injection pressure ranges fromapproximately 1000 to 2000 bar.
Figure 1. Examples of chamber geometries within thesearch space. The present geometric parameters
included in the optimization studies are illustrated.
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Table 1. Design parameters, ranges, and resolutions.
Parameter Range Resolution
bowl diam. 2 37 cm (small-bore)511.7 cm (large-bore)
16
bowl depth 5090 % max. 16
crown height 2090 % max. 16DOI 12.9528 deg. 16
hole size frac 0100 % max. 16injection angle 2080 deg. 32
SOI -155 deg. atdc 16swirl ratio 04 8
EGR 050 % 16
The actual hole size used in the simulation is calculatedfrom the hole size fraction by
Anozdiameter
*4
=(1)
where
( )[ ] minminmax* AAAfracAnoz += (2)
TinjVholesnum
injmassCA
fuel min***_
_*max 1
= (3)
TinjVholesnum
injmassCA
fuel max***_
_*min
1
= (4)
and frac is the nozzle hole fraction taken from the GAcode. Num_holes is the number of holes per nozzle.Vmin and Vmax are the minimum and maximuminjection velocities, respectively, based on the range of
injection pressure used. Tinj is the time duration ofinjection. C1 is a constant that accounts for the deviationfrom a square rate shape of injection, which is assumed
in equations 1-4. This method allows the injectionduration to vary, independent of the injection pressure.
The bowl depth is calculated from the bowl
depth fraction by
= 2**_ tdcVol
fracdepthbowl (5)
where frac is the bowl depth fraction, Voltdc is the volume
at TDC, and is the bowl radius.A small-bore direct injection diesel engine and a
heavy-duty direct injection diesel engine are considered
in the current study. The small-bore diesel is a singlecylinder version of a Fiat automotive diesel (Corgard and
Reitz [13]). Engine specifications are given in Table 2.The heavy-duty diesel considered is a single cylinder
version of the 3400 series Caterpillar diese(Montgomery [14]). Engine specifications are given inTable 3. Note that, with the exception of bowl diameter,
all parameters and resolutions are identical for the largeand small-bore engines (see Table 1). However, theminimum and maximum bowl diameters used for the two
engines represent 35% and 85% of their respective boresizes.
Table 2. Small-bore Automotive Engine Specifications.
Engine Type 4 valve DI diesel
Bore x Stroke 82.0 x 90.4 mm
Compression Ratio 18.79:1
Displacement 477 cm3
Piston Geometry reentrant bowl
Intake Ports 1 swirl, 1 tumble
Spray included half angle (deg.) 72.5
Swirl ratio (at IVC) 1.83
Boost pressure (bar) 1.96
Bowl dia. 2(mm) 46Bowl depth frac 1.0Crown height frac 0.07DOI (deg.) 18.3
Hole size frac 1.0 (0.160 mm)
EGR 0 %
IVO 10 BTDCIVC 38 ABDCEVO 38 BBDCEVC 8.5 ATDC
Table 3. Heavy-duty Engine Specifications.
Engine Type 4 valve DI diesel
Bore x Stroke 137.2 x 165.1 mm
Compression Ratio 16.1:1
Displacement 2440 cm3
Piston Geometry Mexican Hat
Combustion Chamber Quiescent
Spray included half angle (deg.) 62.5
Swirl ratio (at IVC) 1.0
Boost pressure (bar) 1.62
Bowl dia. 2 mm 98
Bowl de th frac 0.9
Crown hei ht frac 0.22DOI (deg.) 21
Hole size frac 0.4 (0.188 mm)
EGR 0 %
IVO 32 BTDCIVC 33 ABDCEVO 46 BBDCEVC 29 ATDC
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For both engines an operating condition waschosen that had experimental data available for baseline
validation. For the small-bore diesel the operatingcondition is 1757 rev/min and full load. This operatingcondition has a global equivalence ratio of about 0.72.
For the heavy-duty engine the operating condition is 993rev/min and 75% load. This operating condition resultsin a similar overall equivalence ratio of about 0.77.
These operating conditions were chosen since they areboth high load, near the middle of their respectiveengines speed range (near the torque peak), and have
similar global equivalence ratios. This allows for ameaningful comparison of results between the 2 enginesizes. It is important to note that the optimization is only
at this load and speed and that other loads and speedsmay have different optimums. In the future, as computerspeeds increase, more than one operating condition will
be considered for each function evaluation (i.e., morethan one KIVA-GA run), with appropriate weighting givento each condition.
NUMERICAL MODELS
CFD CODE - The multi-dimensional model used in thepresent study is a modified version of the KIVA-3Vcomputer code [15]. KIVA3V solves for unsteady,
compressible, turbulentreacting flows on finitevolumegrids. With the addition and modification of manysubmodels, this code is now being widely applied and
validated for engine combustion simulations [16]. Thesemodels have been adequately described in the literatureand are only briefly described here.
Turbulent flow within the combustion chamber is
modeled using the RNG k model, modified forvariabledensity engine flows [17], and an improved
temperature wall function model is used to predictgas/wall convective heat transfer. This model accountsfor the effect of thermodynamic variations of gas density
and the increase of the turbulent Prandtl number in theboundary layer [18].
The nozzle flow model of Sarre et al. [19] was
implemented to provide initial conditions for the spraymodel. The model takes into account the nozzlepassage inlet configuration, flow losses and cavitation,
the injection pressure and instantaneous combustionchamber conditions [19]. The injector discharge
coefficient, effective injection velocity and injected liquidblob sizes at the injector exit are calculateddynamically throughout the entire injection event.
The KHRT (KelvinHelmholtz and Rayleigh
Taylor) model is used to model the spray breakup. Thismodel assumes that aerodynamic instabilities (i.e., KHwaves) are responsible for liquid breakup within the
dense core region, and that both aerodynamic and RTaccelerative instabilities form droplets beyond a breakuplength defined by
0
2
1 dCL
=
(6
where 1 and 2 are the liquid and gas densities
respectively, and d0
is the diameter of the injected liquidblob. Furthermore, C is a model constant, which canbe shown to be related to the KH model breakup time
constant [16].The spray model also considers the effects o
drop distortion on the drag coefficient of the drops. The
drops drag coefficient is allowed to change dynamicallybetween that of a sphere (in the case of no distortion)and that of a disk (in the case of maximum distortion)
depending on the conditions surrounding the dropDetails of this and other models are described byRutland et al. [20].
To model diesel engine ignition delay, a multistep kinetics model (Shell model) is used. In the Shel
model [21], eight generic reactions are used to representfuel, intermediate species, and products. The premise of
the Shell model is that degenerate branching plays animportant role in determining the cool flame and the twostage ignition phenomena that are observed during the
autoignition of hydrocarbon fuels. A chain propagationcycle is formulated to describe the history of thebranching agent together with one initiation and two
termination reactions [22]. Diesel spray combustion ismodeled with a characteristic time model, which isexplained in detail by Kong et al. [22].
Soot formation is computed with the model ofHiroyasu and Kadota [23] and soot oxidation is
determined with the Nagle and StricklandConstablemodel [24]. In addition, NOx is modeled with theextended Zeldovich mechanism [25]. A detaileddescription of the implementation of these models is
presented by Patterson et al. [26].The one-dimensional gas dynamics code of Zhu
and Reitz [27] was used to model the gas exchange
processes and provide the initial (IVC) conditions for themulti-dimensional code.
OPTIMIZATION - Although a multidimensional CFDmodel provides a tool for simulating both conventionaand unconventional engine design concepts (e.g., [28],
[29]), an efficient design process must be based on amathematical or statistical scheme which searches aconstraintlimited objective function surface for an
optimum [30]. In this context, the CFD model becomesa function evaluator that calculates the objective functionf(X) to be optimized. Thus, if X is the vector o
parameters, or control factors, to be varied (e.g.injection and/or geometric parameters), the presenoptimization problem can be stated as:
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For an objective function f(X), find X=(X1,X2,X3,...,Xk)which maximizes f(X) subject to possible constraints on
the system.
Affes et al. [31] developed a methodology for IC
engine intake port design utilizing CFD calculations anda numerical calculusbased, or local, optimizationtechnique. Local search techniques are typically highly
dependent on the initial design point and tend to betightly coupled to the solution domain. This tightcoupling enables such methods to take advantage of
solution space characteristics, resulting in relatively fastconvergence to a local optimum. However, constraintssuch as solution continuity and differentiability can
restrict the range of problems that can be optimized withsuch methods.
On the other hand, global search methods place
few constraints on the solution domain and are thusmuch more robust for illbehaved solution spaces. Inaddition, these techniques tend to converge to a global
optimum for multimodal functions with many localextrema. Genetic algorithms are global searchtechniques based on the mechanics of natural selection
which combine a survival of the fittest approach withsome randomization and/or mutation. The SimpleGenetic Algorithm (SGA) can be summarized as
follows [32]:
Individuals are generated through randomselection of the parameter space for each controlfactor, and a population is then produced from theset of individuals.
A model (which may be empirical or multidimensional) is used to evaluate the fitness of eachindividual.
The fittest individuals are allowed to reproduce,resulting in a new generation through combiningthe characteristics from two sets of individuals.Mutations are also allowed through random
changes to a small portion of the population.
The fitness criteria thins out the population by killingoff less suitable solutions. The characteristics of the
individuals tend to converge to the most fit solution
over successive generations.
Genetic algorithms have been successfully applied to
design problems ranging from laser systems [33] toreinforced concrete beams [34] and have also beenused for engine design. Edwards et al. [35] constructed
statistical models from a set of factorial experiments andused a genetic algorithm to optimize these models. Withthis methodology, the responses of emissions, fuel
consumption and combustion noise to control factorssuch as boost pressure, swirl ratio and injection pressure
were assessed over a wide range of engine operatingconditions.
While previous studies (e.g., [35]) used Genetic
Algorithms to optimize empirical models constructedfrom experimental results, the present study uses a
MicroGenetic Algorithm (GA) to automaticallydetermine what designs to simulate and hence drive thenumerical experiments to the optimum. Like the SGA
outlined above, the GA operates on a family, opopulation, of designs. However unlike the SGA, the
mechanics of the GA allow for a very small populationsize, npop. For SGAs, npoptypically ranges from 30 to
200, while the GA of Krishnakumar [36] uses apopulation size of five. As a result, a GA is a muchmore feasible tool for use with multidimensiona
modeling. The GA used in the present study is basedon the GA code of Carroll [37] and can be outlined as
follows:
1. A population of five designs is generated fourare determined randomly and one is the presen
baseline design.
2. The fitness of each design is determined and thefittest individual is carried to the next generation
(elitist strategy).
3. The parents of the remaining four individuals aredetermined using a tournament selection strategy. In
this strategy, designs are paired randomly andadjacent pairs compete to become parents of theremaining four individuals in the following generation
[15].
4. Convergence of the population is checked. If thepopulation is converged, go to step 1 keeping the
current fittest individual as the new baseline. If thepopulation has not converged, go to step 2.
Note that mutations are not applied in the GA sinceenough diversity is introduced after convergence of a population. In addition, Krishnakumar [36] andCarroll [37] have shown that GAs reach the optimum in
fewer function evaluations compared to an SGA for theirtest functions.
OPTIMIZATION METHODOLOGY
This section summarizes the key elements incorporatedin the present design methodology including the baseline
design, constraints, the objective function and itsevaluation, and the search technique.
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BASELINE DESIGNS - The baseline combustionchamber geometry for the small-bore engine is shown in
Fig. 2. The baseline design is a re-entrant type bowlwith a pronounced center crown. For computationalefficiency, a sixty-degree sector of the combustion
chamber was modeled. This is afforded by the six-foldsymmetry inherent with the six-hole fuel injection nozzleand axi-symetric chamber geometry. A baseline
simulation was performed and compared to theexperimental data of Corgard and Reitz [13]. As seen inFigure 3, there is good agreement between the
computed and measured cylinder pressure.The automated mesh generation program used
in the current study was not designed to consider such a
complicated geometry. Therefore, a baseline Mexican-hat geometry starting point for the optimization wasconfigured to match as close as possible the actual
engines bowl radius and crown height.
Figure 2. Small-bore diesel engine baseline
computational mesh used for model validation.
-40 -30 -20 -10 0 10 20 30 40 50 60
0
2
4
6
8
10
12
14
Measured
Predicted
Pressure
(MPa
)
crank angle (deg. ATDC)
Figure 3. Comparison of computed and measuredcylinder pressure for the small-bore diesel baseline
geometry shown in Figure 2.
The baseline combustion chamber geometry forthe heavy-duty engine is shown in figure 4. The
baseline design is an open-type chamber featuring aMexican-hat shape. Again, a baseline simulation wasperformed and compared to experimenta
measurements (Montgomery and Reitz [14, 30]). Figure5 shows the computed and measured cylinder pressurewith good agreement between the two. The successfu
comparisons shown here, along with previous results(not shown, Senecal and Reitz [11, 12]) provideconfidence in the model predictions.
Figure 4. Heavy-duty diesel engine baseline
computational mesh.
-40 -30 -20 -10 0 10 20 30 40 50 60
0
2
4
6
8
10
12
Measured
Predicted
Pressure(MPa)
crank angle (deg. atdc)
Figure 5. Comparison of computed and measuredcylinder pressure for the heavy-duty diesel baselinecase.
OBJECTIVE FUNCTION AND ITS EVALUATION Since the goal of the present optimization process is to
reduce emissions without sacrificing fuel economy, theobjective, or merit, function should contain engineoutNOx, Hydrocarbon (HC) and soot emissions levels, as
well as fuel consumption. In this study, the proposedmerit function of Montgomery and Reitz [14, 30], whichha s also been used by Senecal and Reitz [11, 12], is
used and is given by
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3
2
2
2
1
1000)(
RRRf
++=X
(7)
where
( )01
1HCNOx
HCNOx
++
=WR(8)
02
2PM
PM
WR =
(9)
0
3BSFC
BSFC=R
(10)
and the parameter vector X is defined in Table 1.For the small-bore engine the (NOx + HC)o and
PMo values are 6.015 and 1.481 g/kg-fuel, respectively.
These fuel specific emissions targets were derived fromthe EPA tier II 2004 automotive diesel mandates
(Krieger et al. [38]) using the vehicle road powerrequirements of Stodolsky et al. [39] and an assumptionof 40% brake thermal engine efficiency (approximately
60 miles/gallon diesel fuel). The baseline fuelconsumption BSFCo is taken as 210 g/kW-hr (i.e., 40%brake thermal efficiency). NO emissions were used in
the small-bore optimization.For the heavy-duty engine, the (NOx + HC)o and
PMo values are the EPA mandated on-highway
emissions levels (3.35 and 0.13 g/kWhr, respectively)for 2002/2004 and BSFC0 is a baseline fuel consumption(215 g/kWhr in the present work, obtained form the
experiments of Montgomery [14]). The weightingconstants W1 and W2 are set to 1.0 in the present studyfor both engines. Note that hydrocarbon emissions are
determined from the predicted amount of unburned fuelat the end of each simulation. The brake power in eachcase was calculated using the calculated gross indicated
power and subtracting a baseline pumping and frictionalpower. No correction to the frictional power was madefor changes in the imep.
CONSTRAINTS - As described by Montgomery [14],physical constraints on the heavy-duty engine include a
maximum exhaust temperature of 1023 K and a peak
combustion pressure of approximately 15 MPa. Thepenalty method technique of Senecal [11,12] is used to
inhibit convergence to an unphysical solution (i.e., onethat violates the present constraints). The maximumcylinder pressure limit is taken as 14 MPa for the small-
bore engine. The small-bore exhaust temperature limitwas set equal to that of the heavy -duty engine (i.e., 1023K). The exhaust temperature change during blow-down
was estimated by an isentropic expansion from the
cylinder pressure at exhaust valve opening (EVO) to the
exhaust manifold pressure, assuming a (ratio ospecific heats) of 1.2.
SEARCH TECHNIQUE - The final, and perhaps mosimportant, element of the KIVAGA methodology is the
GA optimization technique described above. TheKIVAGA code is completely automated to simulate aGA generation (i.e., five designs) in parallel. Once thefive simulations are completed, the genetic operatorsproduce a new population and the process is repeated.In this study 80 generations were run (i.e., 400 KIVA
simulations). Representative run times were 2-4 weekson an SGI Origin 2000 supercomputer.
RESULTS AND DISCUSSION
The results from the small-bore optimization are
presented first, followed by the large-bore, and finally a
comparison of results between the two engine sizes ispresented.
SMALL-BORE OPTIMIZATION- Figure 6 presents themaximum merit function curve for the small-bore engine
This curve shows the maximum merit value of eachsuccessive generation. As seen in the figure, theoptimum design at generation eighty has a significantly
higher merit value when compared to the optimizationstarting point. Notice that the predicted optimum did notchange between generations 50 and 80, indicating
convergence. However, convergence is not guaranteed,since the true global optimum is not known a prioriFigure 6 also presents the chamber geometries and
spray included angles corresponding to major merivalue changes. It is interesting to note the evolution ofthe chamber geometry through the optimization process
which started with a small diameter deep bowl, moved toa Mexican hat type geometry, and finally arrived at amore toroidal like geometry with a low center piston
crown. It is important to note that many othegeometries were included in the optimization processand only goemetries associated with maximum merit
changes are shown here. The spray orientation angle ofthe optimum case is shown in Table 4, along with thevalues of all parameters for the optimum designs fo
both engines. As shown in Figure 6, this spray angle
directs the fuel towards the far bottom corner of thebowl.
Figure 7 presents the best design of eachgeneration for six of the parameters, along with themaximum merit curve, for reference. Figure 7 a, b, c, d
e, and f show the bowl diameter, bowl depth fraction,piston crown fraction, injection duration, start of injectiontiming, and spray included half-angle, respectively. The
bowl diameter was initially small, to best match the
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baseline engine geometry. It then moved to a large bowldiameter, dipped back to a slightly smaller diameter,
then finished with a relatively large diameter. The bowldepth fraction moved to a large value early in theoptimization and stayed large to the end.
Interestingly, the piston crown fraction startedlow (high center piston crown height) and moved to alarge value (low center crown height) between
generations 30 and 40. The convergence to a relativelylarge diameter shallow bowl shape is an indication thatthe high injection pressure is sufficient for good mixing
and does not require strong swirl and squish flows.However, it is important to note that this is a mediumspeed operating condition and at high engine speed
more air motion may be required for clean and efficientcombustion.
Up to about generation 50 the injection duration
was shorter than that of the baseline case, however theinjection duration then moved to a larger value (longerinjection duration) where it remained until the end of the
optimization. The spray orientation angle progressivelymoved from smaller to larger values, i.e., moving
towards spraying into the squish volume.Figure 8 presents the best design of each
generation for the remaining three parameters, along
with the maximum merit curve, for reference. Figure 8 ab, and c shows swirl ratio, EGR fraction, and nozzle holediameter, respectively. The swirl ratio was initialized at
approximately 1.8, dipped to 0.0, and converged to 1.1.The reduced swirl, when compared to the baseline, is anindication of a reduced reliance on air motion for mixing.
This can be attributed to the higher injection velocity, aswell as the larger bowl diameter, which has less swirlintensification near TDC. The EGR fraction, which was
initially 0.0 (from the baseline case), converged to 0.23.The nozzle hole diameter, initially 0.16 mm, convergedto 0.11 mm. The final (converged) values for all nine
parameters are shown in Table 4.
0 10 20 30 40 50 60 70 80
150
200
250
300
350
400
450
500
Maximummeritvalue
Generation number
Figure 6: Maximum merit function curve for the small-bore engine optimization study. Also shown are the chamber
geometries corresponding to the major merit value changes.
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0 10 20 30 40 50 60 70 803.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
Bowldiameter(cm)
Generation number
0
50
100
150
200
250
300
350
400
450
500
Maximu
mmeritvalue
(a)
0 10 20 30 40 50 60 70 800.5
0.6
0.7
0.8
0.9
1.0
Bowldepth
fraction
Generation number
0
50
100
150
200250
300
350
400
450
500
Maximummeritvalue
(b)
0 10 20 30 40 50 60 70 800.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Pistoncrownfraction
Generation number
0
50
100
150
200
250
300
350
400
450
500
Maximummeritvalue
(c)
0 10 20 30 40 50 60 70 8012
14
16
18
20
22
24
26
28
Injectionduration(CAdeg.)
Generation number
0
50
100
150
200
250
300
350
400
450
500
Maximummeritvalue
(d)
0 10 20 30 40 50 60 70 80-16-14
-12
-10
-8
-6
-4
-2
0
2
4
6
Star
tofinjectiontiming(CAdeg.ATDC)
Generation number
050
100
150
200
250
300
350
400
450
500
Maximummeritvalue
(e)
0 10 20 30 40 50 60 70 8020
30
40
50
60
70
80
Sprayincludedhalf-angle(deg.)
Generation number
050
100
150
200
250
300
350
400
450
500
Maximummeritvalue
(f)Figure 7: Merit and parameter values for the best design of each generation of the small-bore optimization study. Shown
here are (a) bowl diameter, (b) bowl depth fraction, (c) piston crown fraction, (d) injection duration, (e) start of injectiontiming, and (f) spray included half-angle.
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0 10 20 30 40 50 60 70 80-1.0
-0.5
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Swirlratio
Generation number
0
50
100
150
200
250
300
350
400
450
500
Maxi
mummeritvalue
(a)
0 10 20 30 40 50 60 70 800.0
0.1
0.2
0.3
0.4
0.5
EGRfraction
Generation number
0
50
100
150
200
250
300
350
400450
500
Maximummeritvalue
(b)
0 10 20 30 40 50 60 70 800.10
0.12
0.14
0.16
0.18
0.20
Nozzleholediameter(mm)
Generation number
0
50
100
150
200
250
300
350
400
450
500
Maximummeritvalue
(c)
Figure 8: Merit and parameter values for the bestdesign of each generation of the small-bore optimizationstudy. Shown here are (a) swirl ratio, (b) EGR fraction,
and (c) nozzle hole diameter.
0 2 4 6 8 10 12 14 16 18 20
0
1
2
3
4
soot(g/kg-fuel)
NOx+HC (g/kg-fuel)
Optimization start point
Optimum
Low BSFC case
Figure 9: Soot vs. NOx+HC data from the present small-
bore optimization study (not all points are shown due toscaling) including the optimization start point, optimumand low BSFC cases.
0 2 4 6 8 10 12 1 4 16 1 8 20
190
200
210
220
230
240
BSFC
(g/kW-hr)
NOx+HC (g/kg-fuel)
Optimization start point
Optimum
Low BSFC case
Figure 10: BSFC vs. NOx+HC data from the presensmall-bore optimization study (not all points are showndue to scaling) including the optimization start point
optimum, and low BSFC cases.
has higher TKE prior to injection due to swir
amplification and strong squish flows. After fuel injectioncommences, the optimum and high crown cases TKEraises to a level significantly higher than that of the
baseline case. This is mainly due to the much higherinjection pressure of the optimum and high crowndesigns (2000 bar vs. 1100 bar). In the optimum and
high crown cases it is apparent that the TKE producedfrom the high injection pressure dominates thaproduced from the in-cylinder air motion (i.e., swirl andsquish flows).
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Figure 11. Fuel vapor concentration for the optimumgeometry (top) and high center crown (bottom) in g/cm
3.
-40 -30 -20 -10 0 10 20 30 40 50 60
0
2
4
6
8
10
12
Optimum
High Crown
Pressure(MPa)
crank angle (deg. ATDC)
Figure 12: Comparison of predicted in-cylinder pressurefor the optimum and high crown cases.
-10 0 10 20 30 40 50 60
0
20
40
60
80
100
Optimum
High Crown
Heatreleaserate(J/deg.)
crank angle (deg. ATDC)
Figure 13: Comparison of predicted heat release rate forthe optimum and high crown cases.
0 20 40 60 80 100 120 140 160
0
10
20
30
40
50
60
Baseline (Measured)
Baseline (Predicted)
Optimum
High Crown
NOx(g/kg-fuel)
crank angle (deg. ATDC)
Figure 14: Comparison of predicted NOx for theoptimum, high crown and baseline cases. Circle shows
the measured engine-out NOx for the baseline engine[13].
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0 20 40 60 80 100 120 140 160
0
2
4
6
8
10
12
14
Baseline (Measured)
Baseline (Predicted)
Optimum
High Crown
soot(g/kg-fuel)
crank angle (deg. ATDC)
Figure 15: Comparison of predicted soot for theoptimum, high crown and baseline cases. Circle shows
the measured engine-out soot for the baseline engine[13].
Figure 16. Soot concentration for the baseline enginegeometry at 13 degrees ATDC (top) and 23 degrees
ATDC (bottom) in g/cm3.
Figure 17. Gas velocity magnitude contours at 28
degrees ATDC in cm/s.
-10 0 10 20 30 40 50
0.0
2.0x105
4.0x105
6.0x105
8.0x105
1.0x106
1.2x106
1.4x106
OptimumHigh Crown
Baseline
TKE(cm
2/s
2)
crank angle (deg. ATDC)
Figure 18. Turbulent kinetic energy vs. crank angle forthe optimum, high center crown, and baseline designs.
LARGE-BORE OPTIMIZATION - Figure 19 presents themaximum merit function curve for the large-bore engine
optimization study. As shown in the figure, the optimumdesign has a significantly higher merit value compared tothe present optimization start point, which features the
actual test engine geometry. Notice that the merifunction remains constant from about generation 65onward, indicating convergence of the optimization.
Figure 19 also presents the chamber geometriesand spray included angles corresponding to the major
merit value changes (the baseline geometry and angleare shown for reference). Interestingly, designs withlarge geometric differences are produced during theevolution process (note that many other geometries
were tried in the optimization and only thosecorresponding to the maximum merit are shown, as inFigure 6). During the first 6 generations, deep bowl, low
piston crown designs are favored, while a shallow bowlwith a large radius is the most fit design for generations
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7 through 16. The bowl diameter next decreases alongwith an increase in bowl depth.
Interestingly, the final best geometry (shown inthe upper right of the figure), which remains unchangedafter generation 20, is somewhat similar to the baseline
geometry, however, it includes a slightly wider bowl withless depth and a lower piston crown. The reducedvolume in the bowl is evident in the larger squish height
compared to the baseline geometry. Recall that thecompression ratio was held constant for all geometriesconsidered. The spray included angles for the best-so-
far designs are also shown in Fig. 19 (see arrows). Aswith the geometric parameters, the optimal spray angleremains the same after generation 20 at 68.4 degrees,
which should be compared to the baseline engines 62.5degrees (see table 3).
Although the three parameters defining the bowl
geometry and the spray included half-angle remainconstant after generation 20 for the best-so-far design,
changes in the other 5 parameters result in increases inmerit beyond this point. Figures 20 and 21 present the 9
parameter values for the best design of each generation,along with the corresponding merit curve for reference.Figures 20(a), (b), (c) and (f) illustrate the relatively fast
convergence of the chamber geometry and sprayincluded half-angle. In addition, the swirl ratio convergesvery quickly, as shown in Fig. 21(a). This relatively low
value of about 1.1 is similar to the baseline swirl value of1.0. With the geometry, spray angle and swirl ratioconverged, the remaining generations increased to the
highest merit by looking at different combinations oinjection duration, SOI, EGR and nozzle hole diameter.The final values of the 9 parameters are presented in
Table 4. Note that the optimum design features 10%EGR and a 2000 bar injection pressure with a 0.18 mmnozzle hole diameter
0 10 20 30 40 50 60 70 80
0
50
100
150
200
250
300
Maximummeritvalue
Generation number
Baseline geometry
Figure 19: Maximum merit function curve for the large-bore engine optimization study. Also shown are the chambergeometries and spray included angles corresponding to the major merit value changes.
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0 10 20 30 40 50 60 70 805
6
7
8
9
10
11
12
Bowldiameter(cm)
Generation number
0
50
100
150
200
250
300
Maximum
meritvalue
0 10 20 30 40 50 60 70 800.5
0.6
0.7
0.8
0.9
1.0
Bowldepthfraction
Generation number
0
50
100
150
200
250
300
Maximummeritvalue
0 10 20 30 40 50 60 70 800.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Pistoncrownfraction
Generation number
0
50
100
150
200
250
300
Maximummeritvalue
0 10 20 30 40 50 60 70 8012
14
16
18
20
22
24
26
28
30
Maximummeritvalue
Injectionduration(CAdeg
.)
Generation number
0
50
100
150
200
250
300
0 10 20 30 40 50 60 70 80
-16
-14
-12
-10
-8
-6
-4
-2
0
2
46
Startofinjectiontiming(CAdeg.ATDC)
Generation number
0
50
100
150
200
250
300
Maximummeritvalue
0 10 20 30 40 50 60 70 80
20
30
40
50
60
70
80
Sprayincludedhalf-angle(deg.)
Generation number
0
50
100
150
200
250
300
Maximummeritvalue
Figure 20. Merit and parameter values for the best design for each generation of the large-bore optimization study.
Shown here are the (a) bowl diameter, (b) bowl depth fraction, (c) piston crown fraction, (d) injection duration, (e) start ofinjection timing, and (f) spray included half-angle.
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0 10 20 30 40 50 60 70 800.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Swirlratio
Generation number
0
50
100
150
200
250
300
Maximum
meritvalue
0 10 20 30 40 50 60 70 800.0
0.1
0.2
0.3
0.4
0.5
EGRfraction
Generation number
0
50
100
150
200
250
300
M
aximummeritvalue
0 10 20 30 40 50 60 70 800.16
0.18
0.20
0.22
0.24
0.26
0.28
Nozzleholediameter(mm)
Generation number
0
50
100
150
200
250
300
Maximummeritvalue
Figure 21. Merit and parameter values for the bestdesign for each generation of the large-bore optimization
study. Shown here are the (a) swirl ratio, (b) EGRfraction, and (c) nozzle hole diameter.
Figures 22 and 23 present soot vs. NOx+HC and BSFCvs. NOx+HC, respectively, for the simulation casesperformed in the large-bore optimization study. Also
shown in the figures are target value boxes representingthe mandated emissions and baseline fuel consumption
levels presented above. Figures 22 and 23 also includethe optimization start point and optimum cases (see
arrows). As shown, the optimum case has significantlylower NOx+HC emissions with a slightly lower engineout soot level. In addition, while the optimums BSFC is
higher than the optimization start points value, it is still
well within the target level of 215 g/kW-hr.While the optimum case meets the target levelsof soot and BSFC, it does not meet the 2002/2004mandated NOx+HC levels. On the other hand, theoptimum of Senecal et al. [12] for this engine and
operating condition (0.038 g/kW-hr soot and 2.04 g/kWhr NOx+HC) was well within the mandated emissionslevels. This difference in optima is attributed to the fac
that both boost pressure and split injections wereincluded in the previous optimization study of Senecal etal. [12], but were not included here due to the addition of
the geometric parameters, spray included half-angleswirl ratio and nozzle hole diameter. As shown in Table4, the optimal EGR level is 10% for the present study.
One would expect that more EGR would result in evenlower NOx+HC, but with a penalty in soot. The use ofincreased boost pressure (211 kPa compared to 162
kPa in the present study) and a split injection strategy inthe previous optimization study allowed for reduced NOxwith a higher EGR level of about 17%, with very low soot
emissions. A comparison of the previous and presentoptimization studies indicates the significant influence ofboost pressure (i.e., global air-fuel ratio control) in
meeting future mandated emissions levels.
0 2 4 6 8 10 12 14 16 18 20
0.0
0.2
0.4
0.6
0.8
1.0
soot(g/kW-hr)
NOx+HC (g/kW-hr)
Optimization start pointOptimum
Low emissions case
High ex. temp. cases
Figure 22: Soot vs. NOx+HC data from the presentlarge-bore optimization study (not all points are showndue to scaling) including the optimization start point
optimum, and low emissions cases.
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-10 0 10 20 30 40 50 60
0
5
10
15
20
25
30
Optimum
Optimum with baseline geometry
NOx
(g/kg-fue
l)
crank angle (deg. ATDC)
Figure 26: Comparison of predicted NOx for the large-bore optimum and optimum with baseline (i.e.,production engine) geometry cases.
0 20 40 60 80 100 120 140
0
1
2
3
4
5
6
Optimum
Optimum with baseline geometry
soo
t(g/kg-fue
l)
crank angle (deg. ATDC) Figure 27: Comparison of predicted soot for the large-bore optimum and optimum with baseline (i.e.,
production engine) geometry cases.
COMPARISON OF RESULTS It is interesting to note
from Figures 6 and 19 that the predicted optima for thesmall and large bore engine geometries are remarkablysimi lar (see also Table 4). Both engines favor relatively
large diameter shallow bowls. This is consistent with thehigh injection pressures (2000 bar) found for bothengines optimum designs, where spray induced mixingis favored over swirl-flow induced mixing. Again, athigher engine speeds, higher air motion induced mixingmay be required to maintain good performance. Table 5
presents the predicted optimum values of soot, NOx+HCemissions, and BSFC, all in g/kW-hr, for the small-boreand large bore engines. The small-bore emissions were
converted to g/kW-hr using the BSFC of the optimum.As shown, the large-bore engines optimum has lower
BSFC and soot emissions, but has higher NOx+HCemissions. The higher NOx+HC emissions of the large
bore engine may be attributed to its lower EGR level(i.e., 10% vs. 23%). The convergence to a lower EGRlevel for the large-bore engine may be due to the poorer
air utilization inherent with the large-bore engine, i.e., itmay be more difficult to mix the air and fuel in the largebore engine using one centrally located fuel injector
However, it is also likely due to the target values oemissions chosen. The present small-bore and largebore emission targets are shown again in Table 6. The
small-bore targets were converted to g/kW-hr using theBSFC from the optimum design. As shown, the smallbore targets place more emphasis on NOx+HC
emissions, while the large-bore targets place moreemphasis on soot emissions. The NOx+HC targets forthe large-bore engine are 25 times the soot targets
while the NOx+HC targets are only about 4 times thesoot targets for the small-bore engine. This explainswhy the large-bore engine achieved lower soo
emissions and BSFC than the small-bore engine.
Table 5. Soot, NOx+HC, and BSFC for the optimum
designs, all in g/kW-hr.
Parameter Large-bore Small-bore
Soot 0.115 0.223
NOx+HC 5.0 1.06
BSFC 204 216
Table 6. Soot and NOx+HC emissions targets in g/kWhr.
Parameter Large-bore Small-bore
Soot 0.13 0.32
NOx+HC 3.35 1.3
It is interesting to compare the values of the nineparameters for each engine, from Table 4. The bowgeometries are quite similar, with the small-bore engine
having a slightly larger and deeper bowl, with respect tothe bore. The optimum injection duration, sprayorientation angle, and swirl ratio were found to be the
same for both engines, which may be attributed to thevery similar operating conditions. For the large-boreengine, the start of injection timing is more advanced
and the EGR level is lower, as mentioned above. Thiscan be attributed to the large-bore emission targets
emphasis on low soot emissions.
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CONCLUSIONS
Chamber geometry optimization is an excellentapplication of KIVA-GA since KIVA features 3-Dspatial resolution and thus allows for many designs
to be investigated without actually manufacturing
many different engine components (e.g., pistons,cylinder heads, etc.).
KIVA-GA is an efficient tool for optimizingcombustion systems within the vast search spaceavailable to modern flexible electronically controlled
engines.
Both the small-bore and heavy-duty diesel enginesconsidered favored relatively large diameter shallowpiston bowls, long injection durations at highpressure through small holes, and moderate swirl, at
the operating conditions investigated (i.e., mediumspeed, high load).
The optimum start of injection timing and EGR levelare very sensitive to the NOx target value chosen.
Precise control over the global air / fuel ratio is veryimportant for achieving simultaneous emissions andfuel consumption reductions.
The optimum combustion chamber designs found inthe current study were able to keep the soot awayfrom the combustion chamber walls, where it could
contaminate the lubricating oil and threaten enginelongevity.
ACKNOWLEDGMENTS
The authors would like to thank the following
organizations for their generous support during thecourse of this work: Ford Research Center in Aachen-Germany (FFA), the Army Research Office, Caterpillar
Inc., and DOE / Sandia National Laboratories.
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