汽油机塑料进气歧管型腔设计方法研究
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摘要
塑料进气歧管可比铝进气歧管重量减轻50%以上,发动机动力性得到5～10%的提升,经济性和排放性也有相当改善,材料和制造成本都可得到降低。但是塑料进气歧管作为发动机进气系统最关键的零部件,其设计和制造难度很大。本文主要研究汽油机塑料进气歧管型腔的设计方法。
首先分析了汽油机塑料进气歧管的结构功能及各附件的设计要求,研究了管内气流运动的波动效应和能量损失,提出了汽油机塑料进气歧管型腔的总体设计思路。
研究了内燃机进气过程中一维非定常流动的数值解法。利用一维发动机工作过程仿真软件BOOST,建立了三种不同型号的发动机计算模型,以稳压腔容积,歧管长度、直径作为进气歧管设计过程中的目标优化函数,通过研究各参数对发动机性能的影响,提出设计原则,为进气歧管型腔设计提供基本参数。
借助计算流体力学(CFD)辅助内燃机设计理论,研究了CFD在进气歧管开发中的应用及其模拟精度。利用三维流体计算软件FIRE对所设计的两款塑料进气歧管型腔进行流场模拟,深入研究了型腔内部流场分布和局部压力损失,为型腔的三维结构优化提供理论依据。
对所设计的两款塑料进气歧管制作快速原型样件,分别对其进行发动机装配试验和台架试验。试验结果表明:用该方法设计的塑料进气歧管安装工艺合理,性能符合要求。
本文采用虚拟设计理论,利用现代化集成设计方法,试验与模拟并行,加快了产品开发周期,降低了开发成本,可以高质量的完成设计任务。该方法既可用于指导进气系统的性能改进,还有利于加快国内塑料进气歧管的应用和推广。
Plastic air intake manifolds are successfully replacing aluminum air intake manifolds. Good performance, lower weight and costs are the main reasons behind this trend. But the manifold has an intricate shape owing to its performance and layout requirements, so it is difficult to design and produce. To bring the plastic manifold into practical use in China, this paper mainly researches the design method of plastic air intake manifold cavity for gasoline engine.
Firstly,the configuration function of plastic air intake manifold for gasoline engine was analyzed, and the design requirement of each accessory was proposed. Then the wave resonance and the energy loss of intake manifold were researched in detail, which are important to manifold design. On the base, the way of design plastic air intake manifold cavity was put forward.
After studying the numerical simulation of unsteady flow in intake manifold, 3 different gasoline engine models were set up using simulation software AVL-BOOST. Through one-dimensional engine cycle and gas exchange simulation, the influence of the plenum volume, manifold length and diameter on engine performance were found out. Then the principle of the cavity design was proposed, which can provide the fundamental structure parameters for intake manifold cavity design.
The theory of CFD assisted in engine development was studied. And the mesh structure was also researched which was the key point to compute precision. The three-dimensional numerical simulation of air flows in two plastic air intake manifolds of gasoline engine was performed using CFD software FIRE. The simulated flow field provided a detailed insight into the three-dimensional air flow under different conditions. The calculation results of manifolds flow performance can provide theoretical directions for intake manifold cavity design.
The two plastic intake manifold cavities mold designed with 3D designing software were used to make original samples quickly in the rapid prototype center. The engine test development was finished with these samples, including flow performance assessment, assembly checkout and engine testing. Finally, the testing results showed that this method was reasonable and correct.
The design method of plastic air intake manifold for gasoline engine proposed in
首先分析了汽油机塑料进气歧管的结构功能及各附件的设计要求,研究了管内气流运动的波动效应和能量损失,提出了汽油机塑料进气歧管型腔的总体设计思路。
研究了内燃机进气过程中一维非定常流动的数值解法。利用一维发动机工作过程仿真软件BOOST,建立了三种不同型号的发动机计算模型,以稳压腔容积,歧管长度、直径作为进气歧管设计过程中的目标优化函数,通过研究各参数对发动机性能的影响,提出设计原则,为进气歧管型腔设计提供基本参数。
借助计算流体力学(CFD)辅助内燃机设计理论,研究了CFD在进气歧管开发中的应用及其模拟精度。利用三维流体计算软件FIRE对所设计的两款塑料进气歧管型腔进行流场模拟,深入研究了型腔内部流场分布和局部压力损失,为型腔的三维结构优化提供理论依据。
对所设计的两款塑料进气歧管制作快速原型样件,分别对其进行发动机装配试验和台架试验。试验结果表明:用该方法设计的塑料进气歧管安装工艺合理,性能符合要求。
本文采用虚拟设计理论,利用现代化集成设计方法,试验与模拟并行,加快了产品开发周期,降低了开发成本,可以高质量的完成设计任务。该方法既可用于指导进气系统的性能改进,还有利于加快国内塑料进气歧管的应用和推广。
Plastic air intake manifolds are successfully replacing aluminum air intake manifolds. Good performance, lower weight and costs are the main reasons behind this trend. But the manifold has an intricate shape owing to its performance and layout requirements, so it is difficult to design and produce. To bring the plastic manifold into practical use in China, this paper mainly researches the design method of plastic air intake manifold cavity for gasoline engine.
Firstly,the configuration function of plastic air intake manifold for gasoline engine was analyzed, and the design requirement of each accessory was proposed. Then the wave resonance and the energy loss of intake manifold were researched in detail, which are important to manifold design. On the base, the way of design plastic air intake manifold cavity was put forward.
After studying the numerical simulation of unsteady flow in intake manifold, 3 different gasoline engine models were set up using simulation software AVL-BOOST. Through one-dimensional engine cycle and gas exchange simulation, the influence of the plenum volume, manifold length and diameter on engine performance were found out. Then the principle of the cavity design was proposed, which can provide the fundamental structure parameters for intake manifold cavity design.
The theory of CFD assisted in engine development was studied. And the mesh structure was also researched which was the key point to compute precision. The three-dimensional numerical simulation of air flows in two plastic air intake manifolds of gasoline engine was performed using CFD software FIRE. The simulated flow field provided a detailed insight into the three-dimensional air flow under different conditions. The calculation results of manifolds flow performance can provide theoretical directions for intake manifold cavity design.
The two plastic intake manifold cavities mold designed with 3D designing software were used to make original samples quickly in the rapid prototype center. The engine test development was finished with these samples, including flow performance assessment, assembly checkout and engine testing. Finally, the testing results showed that this method was reasonable and correct.
The design method of plastic air intake manifold for gasoline engine proposed in
引文
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[3] 朱芝培,汽车零部件塑料化发展趋势,广东塑料,2004,6:54～58
[4] 何铁冰,熔芯法塑料进气歧管的开发和系列生产,塑料开发,1993,20(2) 78～84
[5] Kevin Edwards , Paul Daly, Plastic Intake Manifolds-Geometric Growth for 7 Years, SAE1999-01-0315
[6] Plastic Intake Manifolds - A Commodity, News Release,June,2003
[7] Chul S.Lee,Val Kagan,塑料进气歧管焊接强度的研究,车用发动机,1998,12(6):50～52
[8] 陆淳豪,朱庆棠,塑料灯具摩擦焊原理及应用,汽车电器,1995(6):14～16
[9] Prasanna S. Kondapalli,Venkat Sirani, General Guidelines for Improving Burst Pressure Strength of Welded Nylon Air Intake Manifolds, SAE 2000-01-0040
[10] 张颖,MPI 公司谈进气歧管设计需要专业化经验,汽车与配件,2004,10
[11] Minoru Chuubachi, Katsuji Douke, Moriji Hiraishi et al, Development of a Highly Efficient Manufacturing Method for a Plastic Intake Manifold, SAE 2002-01-0605
[12] Sigeo Tsukakoshi,Hisakazu Miya and Mitsuhiro Miyake, Development of a Plastic Intake Manifold,SAE 930085
[13] Holger Paffrath, Matthias Alex and Karl-Ernst Hummel, Technology for Future Air Intake Systems,SAE 1999-01-0266
[14]周龙保,内燃机学,北京:机械工业出版社,2000
[15]细川武志编,魏朗译,汽车构造图册,北京:人民交通出版社,2005,52～265
[16] 蔡兴旺,汽车构造与原理(下册 底盘、车身),北京:机械工业出版社,2004,261～266
[17]张礼林,杜艳明,柴油机进气管惯性增压的试验研究,现代车用动力,2003.8,22～25
[18]杨建华,龚金科,吴义虎,内燃机性能提高技术,北京:人民交通出版社,2000,87～91
[19]Liu J P, J F Bingham, Effects of Intake System Dimensions on Volumetric Efficiency-Speed Characteristics of Multi-Cylinder Engines,内燃机学报,1997,15(3),257～266
[20]Royo R,Corberanj·PerezA ,Optimal Design of the Intake System in 4-S.I.C.E,SAE Paper 9402l0
[21]孔珑,工程流体力学,北京:中国电力出版社,1998,72～77,102～127
[22]张也影,流体力学,北京:高等教育出版社,2000
[23]K.V.Tallio, B.J.Tobis and A.Selamet, The Application of Steady-Flow Loss Correlations to Intake Manifold Design, SAE Paper 930608
[24]AVL-BOOST V4.0.1 User’s Guide, March 2003,2-48～2-52
[25]Morel I,Lapointe L A,Concurrent Simulation and Testing Concept in Engine Development, SAE 940207
[26]A Harten, Uniformly High Order Accurate Essentially Non-Oscillatory Schemes III, Journal of Computational Physics,1997, 131(1):3～47
[27]朱小慧,顾宏中,模拟一维非定常流动的FVM-TVD法 ,内燃机学报,2001,19(2):169～172
[28]顾宏中,内燃机中气体流动及数值分析,北京:国防工业出版社,1985,62～91
[29]朱访君,吴坚,北京:国防工业出版社,1997,136～143
[30][英]R.S.本森 著,程宏,朱倩,邵明锋 译,内燃机的热力学和空气动力学,北京:机械工业出版社,1986
[31]Oldrich Vítek, Milo? Polá?ek, Tuned Manifold Systems-Application of 1-D Pipe Model, SAE 2002-01-0004
[32]T. Bulaty, H. Niessner, “Calculation of 1-D Unsteady Flows in Pipe Systems of I.C. Engines”, Journal of Fluids Engineering, Vol. 107, Sept 1985
[33]B. Peters and A. D. Gosman, Numerical Simulation of Unsteady Flow in Engine Intake Manifolds, SAE930609
[34]Elbert Hendricks, Alain Chevalier, Michael Jensen et al, Modeling of the Intake Manifold Filling Dynamics, SAE960037
[35]D. E. Winterbone, M. Yoshitomi, “The Accuracy of Calculating Wave Action in Engine Intake Manifolds”, SAE Paper900677
[36]方适应,邓康耀,崔静等,进排气管一维非定常流动计算方法的比较,车用发动机,2000,6(3):22～25
[37]G. P. Blair, S. J. Kirkpatrick. Experimental Validation of 1-D Modeling Codes for a Pipe System Containing Area Discontinuities. SAE Paper 950276,488～501
[38]D. Levy, Gabriella Puppo,On the Behavior of the Total Variation in CWENO Methods for Conservation Laws, Applied Numerical Mathematics,2000(33):407～414
[39]焦天民,周龙保,内燃机进气系统模拟计算新方法研究,车用发动机,2002,137(1):5～7
[40]何玲,电喷发动机可变进排气系统的研究:[硕士学位论文],黑龙江;哈尔滨工业大学工学,2003
[41]Azoury P H,Engineering applications of unsteady fluid flow, England: JohnWilery & Sons, 1992
[42]Stone C R, Review of induction system design and a comparison between prediction and results from a single cylinder diesel engine, SAE Paper 921727
[43]蒋炎坤,CFD辅助发动机工程的理论与研究,北京:科学出版社,2004
[44]沈俊,傅立敏,黎妹红等,CFD软件及其在汽车领域的应用,汽车研究与开发,2000(5):25～28
[45]周松,刘子强,内燃机分支管道三维不稳定流场的数值模拟,哈尔滨工程大学学报,2003(3):268～272
[46]AVL-Fire Version 8.2 CFD WORKFLOW MANAGER v1.2 User’s Guide , July 2003
[47]Franz J.Laimbiick, Gerhard Meister and Simon Grilc, CFD Application in Compact Engine Development, SAE 982016 1980～1984, 2026～2028
[48]Toshihiko Kuriyama, Necessity of Reevaluation and Replacement of CFD Software,自动车技术,1999,4
[49]Kuo T W,Hang S M,Three-Dimensional Steady Flow Computations in Manifold-Type Junctions and a Comparison with Experiment, SAE Paper 932511
[50]Pierre Godrie, Simulation of Flow Field Generated by Intake Port-Valve-Cylinder Configurations-Comparisons Measurements and Applications, SAE 940521
[51]毛崎波,蔡忆昔,用多重网格法研究多缸内燃机的进气特性,内燃机学报,1999,17(2):182～185
[52]王春发,陈国华,杨万里等,螺旋气道三维分块结构化贴体网格的生成,小型内燃机与摩托车,2003,32(4):23～25
[53]罗马吉,陈国华,蒋炎坤等,多缸内燃机进气系统流动计算的分块结构化网格设计,柴油机设计与制造,2000(4):19～20
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[56]许元默,帅石金,王建昕,电喷汽油机进气歧管的 CAD/CFD 设计,汽车工程,2002,24(4):314～317
[57]Xing Yang Liu, William Wells, Millan Yeung et al, Plastic Manifold Rapid Prototyping Advances, SAE 1999-01-0314
[58]沈祖京,用热线风速仪测量内燃机缸内流场时热线探针的方向敏感性研究,内燃机学报,1990,8(1):19～26
[59]吴小江,发动机进气管中气流流速的测量,农机化研究,2002,1(2):99～101
[60]李伟,李康,杨丽华,CA498 柴油发动机进气歧管出口流速分布测量,汽车技术,1999,10,17～21
[61]王健,四气门汽油机气流运动及其对混合气形成影响的研究:[博士学位论文],天津:天津大学,2002
[62]胡华,FOX650 四气门汽油机进气流动特征及其缸内流场的研究:[硕士学位论文],天津:天津大学,2002
[2] 李光耀,任广英,刘少文等,塑料在汽车工业的应用及发展前景,重型汽车,2004,3:20～22
[3] 朱芝培,汽车零部件塑料化发展趋势,广东塑料,2004,6:54～58
[4] 何铁冰,熔芯法塑料进气歧管的开发和系列生产,塑料开发,1993,20(2) 78～84
[5] Kevin Edwards , Paul Daly, Plastic Intake Manifolds-Geometric Growth for 7 Years, SAE1999-01-0315
[6] Plastic Intake Manifolds - A Commodity, News Release,June,2003
[7] Chul S.Lee,Val Kagan,塑料进气歧管焊接强度的研究,车用发动机,1998,12(6):50～52
[8] 陆淳豪,朱庆棠,塑料灯具摩擦焊原理及应用,汽车电器,1995(6):14～16
[9] Prasanna S. Kondapalli,Venkat Sirani, General Guidelines for Improving Burst Pressure Strength of Welded Nylon Air Intake Manifolds, SAE 2000-01-0040
[10] 张颖,MPI 公司谈进气歧管设计需要专业化经验,汽车与配件,2004,10
[11] Minoru Chuubachi, Katsuji Douke, Moriji Hiraishi et al, Development of a Highly Efficient Manufacturing Method for a Plastic Intake Manifold, SAE 2002-01-0605
[12] Sigeo Tsukakoshi,Hisakazu Miya and Mitsuhiro Miyake, Development of a Plastic Intake Manifold,SAE 930085
[13] Holger Paffrath, Matthias Alex and Karl-Ernst Hummel, Technology for Future Air Intake Systems,SAE 1999-01-0266
[14]周龙保,内燃机学,北京:机械工业出版社,2000
[15]细川武志编,魏朗译,汽车构造图册,北京:人民交通出版社,2005,52～265
[16] 蔡兴旺,汽车构造与原理(下册 底盘、车身),北京:机械工业出版社,2004,261～266
[17]张礼林,杜艳明,柴油机进气管惯性增压的试验研究,现代车用动力,2003.8,22～25
[18]杨建华,龚金科,吴义虎,内燃机性能提高技术,北京:人民交通出版社,2000,87～91
[19]Liu J P, J F Bingham, Effects of Intake System Dimensions on Volumetric Efficiency-Speed Characteristics of Multi-Cylinder Engines,内燃机学报,1997,15(3),257～266
[20]Royo R,Corberanj·PerezA ,Optimal Design of the Intake System in 4-S.I.C.E,SAE Paper 9402l0
[21]孔珑,工程流体力学,北京:中国电力出版社,1998,72～77,102～127
[22]张也影,流体力学,北京:高等教育出版社,2000
[23]K.V.Tallio, B.J.Tobis and A.Selamet, The Application of Steady-Flow Loss Correlations to Intake Manifold Design, SAE Paper 930608
[24]AVL-BOOST V4.0.1 User’s Guide, March 2003,2-48～2-52
[25]Morel I,Lapointe L A,Concurrent Simulation and Testing Concept in Engine Development, SAE 940207
[26]A Harten, Uniformly High Order Accurate Essentially Non-Oscillatory Schemes III, Journal of Computational Physics,1997, 131(1):3～47
[27]朱小慧,顾宏中,模拟一维非定常流动的FVM-TVD法 ,内燃机学报,2001,19(2):169～172
[28]顾宏中,内燃机中气体流动及数值分析,北京:国防工业出版社,1985,62～91
[29]朱访君,吴坚,北京:国防工业出版社,1997,136～143
[30][英]R.S.本森 著,程宏,朱倩,邵明锋 译,内燃机的热力学和空气动力学,北京:机械工业出版社,1986
[31]Oldrich Vítek, Milo? Polá?ek, Tuned Manifold Systems-Application of 1-D Pipe Model, SAE 2002-01-0004
[32]T. Bulaty, H. Niessner, “Calculation of 1-D Unsteady Flows in Pipe Systems of I.C. Engines”, Journal of Fluids Engineering, Vol. 107, Sept 1985
[33]B. Peters and A. D. Gosman, Numerical Simulation of Unsteady Flow in Engine Intake Manifolds, SAE930609
[34]Elbert Hendricks, Alain Chevalier, Michael Jensen et al, Modeling of the Intake Manifold Filling Dynamics, SAE960037
[35]D. E. Winterbone, M. Yoshitomi, “The Accuracy of Calculating Wave Action in Engine Intake Manifolds”, SAE Paper900677
[36]方适应,邓康耀,崔静等,进排气管一维非定常流动计算方法的比较,车用发动机,2000,6(3):22～25
[37]G. P. Blair, S. J. Kirkpatrick. Experimental Validation of 1-D Modeling Codes for a Pipe System Containing Area Discontinuities. SAE Paper 950276,488～501
[38]D. Levy, Gabriella Puppo,On the Behavior of the Total Variation in CWENO Methods for Conservation Laws, Applied Numerical Mathematics,2000(33):407～414
[39]焦天民,周龙保,内燃机进气系统模拟计算新方法研究,车用发动机,2002,137(1):5～7
[40]何玲,电喷发动机可变进排气系统的研究:[硕士学位论文],黑龙江;哈尔滨工业大学工学,2003
[41]Azoury P H,Engineering applications of unsteady fluid flow, England: JohnWilery & Sons, 1992
[42]Stone C R, Review of induction system design and a comparison between prediction and results from a single cylinder diesel engine, SAE Paper 921727
[43]蒋炎坤,CFD辅助发动机工程的理论与研究,北京:科学出版社,2004
[44]沈俊,傅立敏,黎妹红等,CFD软件及其在汽车领域的应用,汽车研究与开发,2000(5):25～28
[45]周松,刘子强,内燃机分支管道三维不稳定流场的数值模拟,哈尔滨工程大学学报,2003(3):268～272
[46]AVL-Fire Version 8.2 CFD WORKFLOW MANAGER v1.2 User’s Guide , July 2003
[47]Franz J.Laimbiick, Gerhard Meister and Simon Grilc, CFD Application in Compact Engine Development, SAE 982016 1980～1984, 2026～2028
[48]Toshihiko Kuriyama, Necessity of Reevaluation and Replacement of CFD Software,自动车技术,1999,4
[49]Kuo T W,Hang S M,Three-Dimensional Steady Flow Computations in Manifold-Type Junctions and a Comparison with Experiment, SAE Paper 932511
[50]Pierre Godrie, Simulation of Flow Field Generated by Intake Port-Valve-Cylinder Configurations-Comparisons Measurements and Applications, SAE 940521
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