wave initial stage design

Application of the WAVE system at the initial stages of engine design

Peter A. Golubev, Michael A. Mironychev,

Alexei M. Nesterenkov

OJSC “ZMZ” Russia

Abstract

The paper deals with the results of the WAVE system application

to the optimization of the both gasoline and new diesel engines of the OJSC

“ZMZ” production. The design and test data analysis points to the excellent

convergence of the results in the full range of the engine speed

characteristics. Particular attention is given to the problem of the motor car

intake system design on the basis of the WAVE models. The

recommendations are defined for the optimum intake system assembly

design. The comparison of the design results and the data of the engine

laboratory tests for some variants of motor car intake system are cited in the

paper.

WAVE-simulation and investigation of the engine performance

The engine operation simulation and the WAVE mathematical

model tests were conducted on the base of the following engine types:

a) ZMZ 514.10 in-line 4 cylinder and 4-stroke turbo-supercharged

/ direct-injection diesel engine:

- D/H = 87/94;

- capacity = 2,24 L;

- power = 96KW;

- max. torque = 284NM

2

The engine was developed on the basis of ZMZ 4062.10 series-

produced gasoline engine. Ricardo was involved in the works on the diesel

engine operation optimization.

b) ZMZ 301.10 6- cylinder V-engine:- the angle between the half-blocks =90°;

- electronic fuel injection system;

- D/H = 92/80;

- capacity = 3,2 L;

- power = 155KW;


c) ZMZ 4052.10 in-line 4-cylinder gasoline engine that presents

the modification of series-produced ZMZ 4062.10

- electronic fuel injection system;

- D/H = 95,5/86;

- capacity = 2,5 L;

- power = 112KW;


Engine operation simulation was based on the WAVE-

preprocessor application. Figures 1-3 show engine WAVE-models. To

confirm the calculated and the experiment model adequacy the comparison

of the cylinder volumetric efficiency (K) values used as a criterion.

Figures 4 and 5 show the calculated and the experiment K values

in the whole speed range of ZMZ 514.10 and ZMZ 4052.10 engines. The

results of the analysis indicate that the difference of the calculated and the

experiment K values lies within the experimental error and constitutes 5-8%.

3

Figures 6-8 show the net results of variation of some constructive

parameters for the engine under consideration.

Specifically,

a) the rational geometry of the diesel engine intake channels was

defined that gave the opportunity to increase K value by 12-

15% at low and middle engine speeds ( Fig. 6 and 7);

b) the optimal combination of the value timing phases and the

vale lift law were found for ZMZ 301.10 engine that resulted in

the K value increase by 15% in the whole engine speed range

(Fig. 9) .

WAVE-simulation of the motor car intake system

One of the key challenges of the engine mounting in the motor car

is the selection of the rational intake system design. The design problem is

defined as the optimization of the system geometric parameters to minimize

the hydraulic losses at the input.

Figure 10 shows the 3D CAD-model of the intake system. On the

basis of that model the WAVE-model of the intake system was developed

and, further, combined with the WAVE-model of ZMZ 4052.10 (Fig. 3).

The design problem was to improve the intake element (chamber)

and to minimize the losses at the input. In that case K was again taken as a

criterion of optimum.

Figure 11 shows the net calculated K characteristic curves for the

optimal chamber geometry defining the hydraulic losses at the input of no

more than 1%.

4

Conclusion Remarks

As it is described in the paper WAVE software may be of high

efficiency in application to the structural optimization of engine and

specialized motor car construction elements, e.g. intake system.

WAVE application results in the indisputable advantage in the

period of engine development as well as in considerable reduction of the test

work volume and costs.

The calculation implementation based on the application of

WAVE software and search of optimum using the mathematical test planing

methods is considered as a rather prospective direction of works.

References:

Ricardo Software, WAVE manuals V3.4.2

5

Fig. 1

WAVE-model of the ZMZ 514.10 Engine

6

Fig. 2

WAVE-model ZMZ 301.10 engine

7

Fig.3

WAVE-model ZMZ 4052.10 engine

8

Fig. 4

The calculated and the experiment K values for the ZMZ 514.10

9

Fig. 5

The calculated and the experiment K values for the ZMZ 4052.10

10

Fig. 6

The optimal K value for ZMZ 514.10

11

Fig. 7


12

Fig. 8


13

Fig. 9

3D CAD model of the intake system

14

Fig. 10

The calculated K values for the optimal chamber geometry

wave initial stage design

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