Computational fluid dynamics-fe simulation for the optimization of a cylinder pressure sensor application in a large gas engine

Abstract

This paper reports on the development of a methodology for designing an on-board pressure sensor and its application to a large bore gas engine cylinder head. A simulation combining CFD and FE calculations is set up and supporting measurements are carried out on a single cylinder engine to gain data for calibration of the model and validation of the simulation results. In addition to the crank angle resolved pressure data for the combustion chamber, the measurements include component temperatures in the cylinder head, on-board sensor and the piston, as well as the heat fluxes into the fire deck and the sensor. Based on this experimental data, various submodels of the CFD calculations are investigated, including heat transfer wall models, the nucleate boiling module for the cooling jacket, and the influence of mesh refinements. Special attention has been given to the impact of the combustion model adjustment on the resulting heat transfer. In the FE model, contact conditions between various components, for example valves and valve seat rings, are investigated thoroughly.