Experimental and Numerical Investigation of an Innovative Complex Piston with Enhanced Free Spray Length for the Heavy-Duty Engine Applications

The combustion and emission formation process in heavy-duty compression ignition engines are strongly influenced by the design of the piston bowl, the cylinder charge motion and the performance of the injection system. This paper proposes an innovative complex piston bowl design approach called as ’flower piston’ to improve the combustion process. It can be manufactured using the conventional machining approaches without use of still expensive additive manufacturing techniques. The flower piston features a scooped cavity with an intention of increasing the free fuel spray penetration. The potential of this innovative flower piston is evaluated using a validated 3D CFD model and compared with the results of single cylinder engine experiments at operating points with minimum fuel consumption. The results of the experimental investigations with the flower piston show an improvement in thermal efficiency in comparison to the conventional piston by up to 0.5%. This is due to a faster initial heat release and increased high pressure cycle work. However, the smoke emissions increased threefold due to fuel entrapment into the flower cavities, leading to formation of fuel-rich pockets. Also, the wall heat losses increased twofold with an increase in NOx raw emissions. With increased spray targeting angle, there was a drastic reduction in smoke emissions and an additional improvement in the thermal efficiency.