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An investigation of the fuel heating, vapor formation, and cavitation erosion location patterns inside a five-hole common rail diesel fuel injector, occurring during the early opening period of the needle valve (from 2 μm to 80 μm), discharging at pressures of up to 450 MPa, is presented. Numerical simulations were performed using the explicit density-based solver of the compressible Navier–Stokes (NS) and energy conservation equations. The flow solver was combined with tabulated property data for a four-component diesel fuel surrogate, derived from the perturbed chain statistical associating fluid theory (PC-SAFT) equation of state (EoS), which allowed for a significant amount of the fuel's physical and transport properties to be quantified. The Wall Adapting Local Eddy viscosity (WALE) Large Eddy Simulation (LES) model was used to resolve sub-grid scale turbulence, while a cell-based mesh deformation arbitrary Lagrangian–Eulerian (ALE) formulation was used for modelling the injector's needle valve movement. Friction-induced heating was found to increase significantly when decreasing the pressure. At the same time, the Joule–Thomson cooling effect was calculated for up to 25 degrees K for the local fuel temperature drop relative to the fuel's feed temperature. The extreme injection pressures induced fuel jet velocities in the order of 1100 m/s, affecting the formation of coherent vortical flow structures into the nozzle's sac volume. [ABSTRACT FROM AUTHOR]

In the present numerical study, implicit large eddy simulations (LES) of non-reacting multi-components mixing processes of cryogenic nitrogen and n-dodecane fuel injections under transcritical and supercritical conditions are carried out, using a modified reacting flow solver, originally available in the open source software OpenFOAM®. To this end, the Peng-Robinson (PR) cubic equation of state (EOS) is considered and the solver is modified to account for the real-fluid thermodynamics. At high pressure conditions, the variable transport properties such as dynamic viscosity and thermal conductivity are accurately computed using the Chung transport model. To deal with the multicomponent species mixing, molar averaged homogeneous classical mixing rules are used. For the velocity-pressure coupling, a PIMPLE based compressible algorithm is employed. For both cryogenic and non-cryogenic fuel injections, qualitative and quantitative analyses are performed, and the results show significant effects of the chamber pressure on the mixing processes and entrainment rates. The capability of the proposed numerical model to handle multicomponent species mixing with real-fluid thermophysical properties is demonstrated, in both supercritical and transcritical regimes. [ABSTRACT FROM AUTHOR]