Chiodi M. An innovative 3D-CFD-Approach towards Virtual Development of Internal Combustion Engines
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Marco Chiodi
An Innovative 3D-CFD-Approach towards
Virtual Development of Internal Combustion Engines
VIEWEG+TEUBNER RESEARCH
Marco Chiodi
An Innovative 3D-CFD-
Approach towards
Virtual Development
of Internal Combustion
Engines
VIEWEG+TEUBNER RESEARCH
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The Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie;
detailed bibliographic data are available in the Internet at http://dnb.d-nb.de.
Dissertation der Universität Stuttgart, Fakultät Konstruktions-,
Produktions-und Fahrzeugtechnik, 2010
Hauptberichter: Prof. Dr.-Ing. Michael Bargende
Mitberichter: Prof. Dr.-Ing. Giorgio Rizzoni
Mitberichter: Prof. Dr.-Ing. Federico Millo
Tag der mündlichen Prüfung: 22. Juni 2010
1st Edition 2011
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“O frati”, dissi “che per cento milia
perigli siete giunti a l’occidente,
a questa tanto picciola vigilia
d’i nostri sensi ch’è del rimanente,
non vogliate negar l’esperienza,
di retro al sol, del mondo sanza gente.
Considerate la vostra semenza:
fatti non foste a viver come bruti,
ma per seguir virtute e canoscenza”.
Dante Alighieri
La Divina Commedia,
Inferno XXVI (Ulisse, 112-120)
Acknowledgments
This work has been carried out during my activity in the department of internal combustion
engines of the FKFS and IVK-University of Stuttgart under the direction of
Prof. Dr.-Ing. Michael Bargende. Since 1998 first as research assistant and then as project
manager of 3D-CFD-simulations I have dedicated most of my time in the development of a new
approach in the 3D-CFD-simulation of internal combustion engines, that aims a better
integration in the engine development process. This work wants to be the report of this project.
I specially want to thank Prof. Michael Bargende for the opportunity, motivation, scientific
support and often also scientific inspiration he gave me during all the years. Many thanks to
Prof. Giorgio Rizzoni from the Ohio State University (USA) and Prof. Federico Millo from the
Politecnico di Torino (Italy) first of all for having willingly accepted to be the co-referent of my
work and then for their reliable support and professional opinions all the time.
Also a special thank goes to the Head of Engine Development at Volkswagen Motorsport:
Dr.-Ing. Donatus Wichelhaus for his extraordinary innovative thinking, talent and openness that
have permitted to successfully realize many interesting projects together. I want to thank him
also for having allowed the publication of some results in this work.
Thanks to the colleagues of my team: Oliver Mack (nickname: Meshelangelo, because he is the
Michelangelo of the meshes) and Alessandro Ferrari for the wonderful collaboration. Thanks
also to the other colleagues at the FKFS and IVK-University of Stuttgart (in particular
Hans-Jürgen Berner, Gerd Hitzler, Dr. Dietmar Schmidt and Dr. Michael Grill) for many
interesting scientific discussions and their suggests during all the years that we have worked
together.
Stuttgart, May 2010
Marco Chiodi
Table of Contents
Table of Contents .......................................................................................................................... IX
Abstract ...................................................................................................................................... XV
Zusammenfassung ...................................................................................................................... XIX
Symbols, Subscripts and Abbreviations.................................................................................. XXIII
1 Introduction .................................................................................................... 1
1.1 Society and Transportation ................................................................................................. 1
1.2 The Fascination of Internal Combustion Engines ............................................................... 1
1.3 Internal Combustion Engines and Sustainable Transportation ........................................... 2
1.3.1 Development Targets of Internal Combustion Engines in the Past ............................... 2
1.3.2 The Role of Alternative Engine Concepts ...................................................................... 4
1.3.3 Development Targets of Internal Combustion Engines in the Future ........................... 4
1.3.3.1 General Improvement of actual Solutions ................................................................. 5
1.3.3.2 Downsizing and Turbo-Charging .............................................................................. 5
1.3.3.3 Hybridization ............................................................................................................. 5
1.3.3.4 Development of Innovative Combustion Solutions ................................................... 6
1.3.3.5 Alternative Fuels ........................................................................................................ 6
1.4 How to Face the Complexity of Future Internal-Combustion-Engines .............................. 8
2 Simulation of Internal Combustion Engines ............................................. 10
2.1 Simulation towards Virtual Engine Development ............................................................ 11
2.1.1 One Tool for the Simulation of the Entire Engine? ...................................................... 11
2.1.1.1 Mechanical Numerical Analysis .............................................................................. 12
2.1.1.2 Engine Operating Cycle Analyses ........................................................................... 13
2.1.2 The Future Challenge: an improved Integration of Simulation Tools ......................... 15
2.2 Today’s Repartition of the Resources in Engine Development ........................................ 17
2.3 Introduction to Engine Processes Modeling in the Simulation of the
Operating Cycle ................................................................................................................ 21