Impact of the Primary Break-Up Strategy on the Morphology of GDI Sprays in 3D-CFD Simulations of Multi-Hole Injectors

The scientific literature focusing on the numerical simulation of fuel sprays is rich in
atomization and secondary break-up models. However, it is well known that the predictive capability
of even the most diused models is aected by the combination of injection parameters and operating
conditions, especially backpressure. In this paper, an alternative atomization strategy is proposed for
the 3D-Computational Fluid Dynamics (CFD) simulation of Gasoline Direct Injection (GDI) sprays,
aiming at extending simulation predictive capabilities over a wider range of operating conditions.
In particular, attention is focused on the eects of back pressure, which has a remarkable impact on
both the morphology and the sizing of GDI sprays. 3D-CFD Lagrangian simulations of two dierent
multi-hole injectors are presented. The first injector is a 5-hole GDI prototype unit operated at ambient
conditions. The second one is the well-known Spray G, characterized by a higher back pressure (up
to 0.6 MPa). Numerical results are compared against experiments in terms of liquid penetration
and Phase Doppler Anemometry (PDA) data of droplet sizing/velocity and imaging. CFD results
are demonstrated to be highly sensitive to spray vessel pressure, mainly because of the atomization
strategy. The proposed alternative approach proves to strongly reduce such dependency. Moreover,
in order to further validate the alternative primary break-up strategy adopted for the initialization of
the droplets, an internal nozzle flow simulation is carried out on the Spray G injector, able to provide
information on the characteristic diameter of the liquid column exiting from the nozzle.