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The design trend for light duty diesel engines is towards lower compression ratio and higher turbocharger boost. This can enable higher specific power and lower pollutant emissions to be achieved, but raises concerns that cold start operation might be adversely affected. This is investigated and quantified through the study of a modern light duty diesel engine at two compression ratios and temperatures down to -20ºC. Key indicators of cold start performance are the magnitude and cycle-to-cycle variation of indicated mean effective pressure. Initial studies were carried out at 300 rpm, a speed representative of post-first-fire conditions. Studies were then conducted at higher engine speeds representative of cold idle. The utility of different injection strategies, timings and quantities is investigated when varying test temperature and engine speed through a range of values encountered during the cold start phase of engine operation. The importance of the glow plug as a cold start aid is also investigated by varying its operating temperature and protrusion into the combustion chamber. The indicated mean effective pressure was used to assess the effects of varying input parameters, and gross heat release rate information is used to identify the phenomena responsible for desirable or undesirable characteristics. Reduction in compression ratio led to no deterioration of initial start performance from speeds just above cranking, provided an appropriate injection strategy was chosen. Higher indicated mean effective pressure was possible at low speeds using low compression ratio due to reduced losses and more complete combustion. Cycle-to-cycle variability in indicated mean effective pressure increased markedly for both compression ratios at engine speeds representative of cold idle, especially when test temperature was reduced. Stability reduction was more severe at low compression ratio. Multiple pilot injections at high compression ratio cold idle resulted in better cycle-to-cycle stability. Analysis of heat release profiles suggested that additional pilots assisted fuel mixing, a conclusion supported by a computational fluid dynamics model. Multiple pilots created a more homogeneous fuel distribution through the bowl at time of main injection. Multiple pilots could not stabilise operation at low compression ratio. Improvement in cold idle at low compression ratio was achieved by increasing glow plug temperature, which significantly increased the rate of fuel preparation. This increased the initial rate of heat release and resulted in significantly less variation in the heat release rate profiles. Small changes in glow plug protrusion rapidly degraded cold idle performance, indicating the importance of correct design.

Partially-premixed Charge Compression Ignition (PCCI) combustion is defined by increased levels of premixed charge whilst retaining control over combustion through injection timing. An experimental investigation has been carried out on a current generation DI diesel engine, equipped with High Pressure Common Rail (HPCR) fuel injection equipment and an external Exhaust Gas Recirculation (EGR) system. The aims of the investigation were to determine the constraints imposed on operating a PCCI combustion strategy with the aim of simultaneously reducing engine-out net soot and NOx emissions. The work was carried out at fully-warm steady-state conditions at engine speeds of 1500 rpm and 1800 rpm, predominantly using a single injection strategy. With a single injection the Start of Injection (SOI), fuel rail pressure, and rate of EGR have been examined with a view to realising PCCI combustion. Timing ranges of -20º to +3ºATDC, rail pressures of 500-1200 bar, and EGR rates of 0-60% have been investigated. The responses looked at have been engine-out soot, NOx, HC, and CO emissions, fuel consumption, and combustion noise. It is shown that variation of the parameters has allowed PCCI combustion to be achieved in a restricted operating region, offering improvement in the NOx-soot trade-off. This region is limited on the available test engine by oxygen availability due to the specifications of the turbocharger and EGR systems. Engine speeds up to 2000 rpm (at 2.5 bar BMEP), and loads of 4.4 bar gross IMEP (at 1500 rpm) have been found to be the limits, beyond which soot and CO emissions rise excessively. It is shown that enhancing the mixing time and intensity are both desirable in achieving PCCI combustion. The net soot reduction mechanism exploited with PCCI combustion strategies is reducing soot formation to outweigh the reduction in oxidation. Enhancing the mixing intensity by increasing injection pressure is highly effective at reducing soot output, but at the expense of brake specific fuel consumption. Increasing the mixing time can also be effective in reducing soot output, but careful parameter selection is required to avoid excessive soot output. Retarded or highly advanced injection timings are shown to reduce net soot output, but both have associated trade-offs and penalties. Retarding combustion is effective at lowering soot and NOx emissions with low associated noise, but a fuel economy penalty is paid. Advanced combustion phasing can result in large peak rates of increase of pressure, which have been shown to correlate well with combustion noise. Overall soot reductions of up to 97% were achieved, but with associated penalties. One of the most acceptable reductions of ~90% came at the cost of a 6% increase in fuel consumption, highlighting that improvements in emissions are achievable with PCCI strategies with acceptable trade-offs.

An experimental investigation of post-start cold idling behaviour has been carried out on a modern single-cylinder HPCR DI light duty diesel engine with a low compression ratio of 15.5:1 at temperatures between 10 and -20°C. The trend toward lower compression ratios from more common values of around 22:1 a few years ago has resulted in lower compression pressures and temperatures, which negatively affects cold idle operation. Improvements in cycle-by-cycle stability of indicated work output through fuel injection strategy and glow plug temperature changes have been explored. This is important to improve NVH and the consumer’s perception of vehicle quality. The key effects on heat release characteristics have been identified and the associated impact on stability discussed. High speed imaging of ignition in a combustion bomb has been used to aid interpretation of engine results. Up to four pilot injections placed in advance of the main have been used. Shorter separation between pilots and pilot-to-main improves stability independent of the number of pilot injections and extends the range of main injection timings to meet target stability of 10% or lower at -20°C. Increasing the number of pilot injections was effective in stabilising combustion at all investigated soak temperatures at fuelling levels producing indicated work required to match friction and ancillary demands. Stability can be susceptible to deterioration at moderate soak temperatures because fuelling demand is relatively low. If a high number of pilot injections are to be avoided to reduce potential wear, then increasing main injection quantity is an effective method to stabilise combustion for a lower pilot number strategy but any increase above target load has to be harnessed by additional ancillary devices. Very high glow plug temperatures of up to 1200°C were examined using a smaller diameter tip ceramic type design. Stable combustion cannot be achieved through higher glow plug temperatures alone. A temperature of 1000°C, which can be achieved using a low voltage metallic type, is adequate to stabilise combustion when combined with a triple-pilot strategy at sub-zero temperatures. The best stability is achieved using 1200°C, which can only be achieved using a more expensive ceramic type, in combination with a triple-pilot strategy producing the desirable target of ~5% or below; the effects are not mutually exclusive. At high glow plug temperatures and using three or four pilot injections, stability improved with warmer soak temperatures. At -5°C, stability was relatively poor when one or two pilots were used irrespective of glow plug temperature. A high premixed contribution to main combustion is associated with improved stability. Minimum threshold values are necessary to stabilise combustion: ~25 J/° at -20°C, ~20 J/° at -5°C and only ~10 J/° at 10°C. A higher number of pilot injections raises pilot induced combustion and improves mixture distribution. These effects subsequently increase the premixed combustion and help sustain a strong main development with less variability. This benefit is maximised when using hotter glow plug temperatures raising IMEPg magnitude and reducing variation.

The research reported in the thesis addresses questions of how engine fuel consumption and carbon dioxide emissions are can be reduced through improvements in thermal management, lubricant design, and energy recovery. The investigations are based on simulation studies using computational models and sub-models developed or revised during the work, and results provided by complementary experimental studies carried out by collaborating investigators. The brake thermal efficiency of the internal combustion engines (ICE) used in cars and light duty commercial vehicles is reduced by frictional losses. These losses vary with engine design, lubricant formulation and thermal state. They are most significant when the engine is running cold or partially warm. Over the New European Drive Cycle (NEDC), engine friction losses raise vehicle fuel consumption by several percentage points. A version of the computational model, PROMETS, has been developed and applied in studies of thermal behaviour, friction and engine lubricant to investigate the performance of a 2.0l, I4 GTDI spark ignition engine and in particular, how these influence fuel consumption over the NEDC. Core parts of PROMETS include a physics-based, empirically calibrated friction model, a cycle averaged description of gas-to-structure heat transfer and a lumped capacity description of thermal behaviour of the engine block and cylinder head. In the thesis, revisions to the description of friction and interactions between friction, local thermal conditions and lubricant are reported. It is shown that the bulk temperature of coolant rather than oil has the stronger influence on friction at the piston-liner interface, whilst bulk oil temperature more strongly influences friction in crankshaft bearings and other lower engine components. However, local oil film temperatures have a direct influence on local friction contribution. To account for this, local values of oil temperature and viscosity are used in describing local friction contributions. Implementation required an oil system model to be developed; an iterative model of the frictional dissipation within the main bearings, and a prediction of piston cooling jet heat transfer coefficients have been added to the oil circuit. Simulations of a range of scenarios and design changes are presented and analysed in the thesis. The size of the fuel savings that could potentially be made through improved thermal management has been demonstrated to be 4.5% for the engine being simulated. Model results show that of the friction contributing surfaces, the piston group is responsible for the highest levels of friction, and also exhibits the largest absolute reduction in friction as the temperature of the engine rises. The relatively low warm-up rate of the lower engine structure gives a correspondingly slow reduction in friction in crankshaft bearings from their cold start values. Measures to accelerate this reduction by raising oil temperature have limited effect unless the strong thermal links between the oil and the surrounding metal are broken. When additional heating is applied to the engine oil, only around 30% is retained to raise the oil temperature due to these thermal links.

The investigation reported in this thesis is concerned with the topic of soot formation and soot particle motion in the cylinder of a light duty automotive diesel engine. CFD has been employed to simulate in-cylinder conditions and to investigate the source of particles which are transferred to the oil. The accumulation of soot in the lubricating oil of diesel engines is one of the factors limiting the interval between oil changes and hence service interval. Soot particles can be transferred to oil film on the cylinder wall layers through the complex motion of the fluid flow in the cylinder. The paths of soot particles from specific in-cylinder locations and crank angle instants have been explored using the results for cylinder charge motion predicted by the Kiva-3v CFD code. Using the velocity fields from the simulation data, massless tracking of the in-cylinder soot particles in space and time is carried out employing a particle tracking with trilinear interpolation technique. From this investigation, new computational codes for the prediction of soot particle paths and soot particle size change along a specific path in a diesel engine have been developed. This investigation is the first numerical study into soot particle trajectories within an engine and thus opens up a novel branch of research of soot formation within internal combustion engines. Computed soot paths from the investigation show that soot particles formed just below the fuel spray axis inside the middle bowl area during early injection period are more likely sources of soot particles on the cylinder wall layers than those formed later. Soot particles that are formed above the fuel axis have less tendency to be transported to the cylinder wall layers thus are not likely to be the main source of soot at the cylinder walls. Soot particles that are from the bowl rim area are found to be another source of soot transfer to the boundary layer, as they are directly exposed to reverse squish motion during the expansion stroke. Soot particles that are formed near the cylinder jet axis during fuel injection tend to move into the bowl. These soot particles are found to be from the relatively less concentrated area. In contrast, particles from the most concentrated areas tend to be moving into the bowl and pose least risk of contaminating oil films on the liner. Sensitivity studies of soot particle paths to swirl show that engine operating with low swirl ratios are more vulnerable to soot in oil problem as low swirls cause the bulk fluid flow to be moving closer to the cylinder walls due to fuel jet velocity and reverse squish motions. Decreasing the spray angle lessens the possibilities of soot particles from being transported close the cylinder wall layers while increasing the spray angle increases the possibilities of soot from the bowl region to be transported close to the cylinder wall layers. The temporal and spatial evolution of soot particle size can be predicted by using the history of temperature, pressure and gas species along the paths. An explorative investigation has been carried out to determine the most suitable method to tackle this soot particle evolution. With proper multipliers, all approaches perform quite satisfactorily in terms of predicting the trend of size change. Soot particles that are likely to be transferred to the cylinder wall layers are predicted to change in size parallel to the average mass profile in the whole cylinder where they quickly peak to maximum at around 18° CA ATDC, and gradually decrease in size through EVO.

The crankshaft is a complex component, and as such, the influence of its geometric parameters on stresses seen under service loads is not well understood. The objectives of this work are to investigate the effects of a wide range of geometric parameters on stresses in overlapped crankshafts, to find correlation between results and to formulate simple methods of predicting peak stress levels: It is intended to achieve this by use of the Finite Element (FE) and Boundary Element (BE) methods. Individual crankthrows are loaded under the important load cases of bending and torsion. Stress concentration factors are determined by normalising peak stresses with respect to the nominal stress occurring in the most appropriate section in the neck between the fillets. Analyses are carried out in 2D and 3D, making use of symmetry as far as possible. Many of the governing dimensions of the crankthrow are included in the analyses; crankpin and journal diameters, crankpin and journal overlap, and web thickness. Variations in SCF are plotted over a wide range for each of these parameters. Additionally, features such as fillet size and shape, bore-holes, dimples, cut-back webs and oil holes are investigated. It is found that the effects on stress of individual parameter changes can be superimposed to accurately predict the effect of combining various parameter changes in one model. The crankpin and journal fillet radii and the length of the minimum section between the fillets are shown to be the critical parameters in determining the peak stress levels in the crankshaft. SCFs obtained from the range of analyses performed show good agreement with the classical theory of SCFs in notched bars. Bore-holes and dimples are found to offer significant benefits in terms of peak stress reduction, in addition to their common usage of reducing the out of balance crankpin mass. The FE and BE methods give accurate results for stress analysis of crankshafts and offer several advantages over traditional experimental techniques; they are ideally suited to parametric analyses, can be carried out relatively quickly, results are repeatable because boundary conditions can be exactly defined, and the cost of analysis is significantly reduced.

Cylinder pressure analysis is widely used in the experimental investigation of combustion processes within gasoline engines. A pressure record can be processed to reveal detail of charge burning, which is a good indicator of combustion quality. The thesis describes the evaluation of an approximate technique for calculating the mass fraction of the charge that has burnt; a novel approach for determining heat loss to the block; the development of a powerful system for combustion analysis; and the investigation of the correlation between the crank angle location of the 50% mass burnt and minimum timing advance necessary to obtain the maximum engine torque. A detailed examination has been carried out into the uncertainties in the determination of the mass fraction burnt as suggested by Rassweiler and Withrow. A revised procedure has been developed which does not require a priori identification of the combustion end point, and a new approach is suggested to calculate the polytropic indices necessary for the pressure processing. This particular implementation of the analysis is able to identify late burning and misfiring cycles, and then take appropriate steps to ensure their proper analysis. The problems associated with the assumption of uniform pressure; alignment of the pressure changes to the volume changes; pressure sampling rate; clearance volume estimation; and calibrating the acquired pressure to absolute are also evaluated. A novel method is developed to ascertain, directly from the pressure history, the heat loss to the cylinder block. Both experimental and simulated data are used to support the accuracy of the suggested heat loss evaluation, and the sensitivity of the method to its inputs is examined. The conversion of procedures for combustion analysis into a format suitable for undertaking high speed analysis is described. The analysis techniques were implemented so that the engine can be considered to be on-line to the analysis system. The system was entitled Quikburn. This system can process an unlimited number of cycles at a particular running condition, updating the screen every 1.5 seconds. The analysis system has been used to study the potentially beneficial correlation between the location of the 50% mass burnt and MBT. The correlation is examined in detail, and found to be valid except under lean fueling conditions, which is seen to be caused by slow flame initiation. It is suggested that the optimum location of the 50% mass burnt can be used as a reference setting for the ignition timing, and as an indicator of combustion chamber performance. An engine simulation was employed to verify that changes in bum shape account for the small variation seen in the optimum 50% bum locations at different operating conditions of the engine. The bum shape changes also account for the range of optimum locations of the 50% mass burnt encountered in different engines.

This thesis describes research undertaken to establish the advantages and disadvantages of using high pressure common rail fuel injection systems with multiple injection capabilities. The areas covered are detailed as follows. Oscillations in the rail pressure due to the opening of the injector can affect the quantity of fuel injected in subsequent injection events. The source of these oscillations has been investigated. A method of damping or reducing the oscillations has been defined and was applied. This successfully reduced the level of unpredictability of the quantity of injected fuel in subsequent injection events. A relationship between needle lift, injection pressure and the quantity of fuel injected was established. The effects of fuel injection parameters (main injection timing, split main separation and ratio) and engine operating parameters (boost pressure and EGR level) on emissions formations and fuel economy have been investigated at five operating points. Design of Experiments techniques were applied to investigate the effect of variables on pollutant emissions and fuel consumption. The sensitivity and linearity of responses to parameter changes have been analysed to assess the extent to which linear extrapolations will describe changes in smoke number (FSN) and oxides of nitrogen (NOx); and which parameters are the least constricting when it comes to adjustments of parameter settings on the FSN-NOx map. Comparing results for split main and single injection strategies at the five operating conditions shows that split main injection can be exploited to reduce NOx or FSN values at all conditions and both NOx and FSN simultaneously at high load conditions. The influence of changing engine speed and brake mean effective pressure (BMEP) on FSN and NOx emissions with given fixed values of parameter settings has been investigated. This established how much of the operating map could be covered by discrete calibration settings. Finally the variation in parameter settings required to maintain fixed FSN and NOx values across the operating map, near the optimum trade-off on the FSN-NOx map, was analysed. Combining the information gained from the individual investigations carried out highlighted some techniques that can be used to simplify the calibration task across the operating map, while also reducing the amount of experimental testing required.

The work described in this thesis concerns the continued development and application of a computational model to simulate the thermal behaviour of internal combustion engines. The model provides information on temperature and heat flow distributions within the engine structure, and on temperatures of oil, coolant and engine-out exhaust gas. Sub-models calculate friction levels, fuel flow rates and gas-side heat transfer, including the effects of exhaust gas recirculation (EGR), spark advance and turbocharging. The effects of auxiliary components such as a cabin heater, oil cooler, intercooler, supplementary heater and EGR cooler can also be simulated. Model developments are aligned towards improving the accessibility of the model and the scope of engine systems that can be simulated. Early versions of the model have been converted from 'C' into the current MATLAB/Simulink versions. The model structure and conversion process are described. New developments undertaken have focused on the external coolant circuit and include the modelling of the thermostat and radiator. A semi-empirical thermostat model is presented. A radiator model based on the effectiveness-NTU method is described. Simulations using the developed model, including the thermostat and radiator sub-models, investigate the effect of thermostat position on engine thermal behaviour. Positioning the thermostat on the inlet to the engine reduces thermal shock. Applications of the model to investigations of sensitivity and performance illustrate the accuracy of and confidence in model predictions. Assessments demonstrate that the model is relatively insensitive to variations of 100/0 in user inputs and is very sensitive to model assumptions if simulation conditions, implied in the model assumptions, are not matched to test conditions. A process for evaluating model performance is described. Evaluation exercises applied to three different engines demonstrate that values predicted by the model are to within 5 to 10% of experimental values. Investigations using the model of methods to improve warm-up times and fuel consumption prior to fully warm conditions show the benefits or otherwise of reduced thermal capacity, an oil cooler, a sump oil heater and an oil-exhaust gas heat exchanger. Each method is assessed over the New European Drive Cycle (NEDC) from a -10°C start. Of these methods, a combined reduction in coolant volume and engine structural mass is most beneficial for reducing coolant warm-up times. An oil-exhaust gas heat exchanger produces the greatest reduction in fuel consumption.