In-cylinder flow control in a four-valve spark ignition engine: numerical and experimental steady rig tests

Computational fluid dynamic (CFD) simulations and experimental steady flow tests (flow discharge, swirl, and tumble) were carried out to study the in-cylinder flow in a commercial four-valve spark ignition engine. The present investigation was aimed at analysing and controlling the generation of macro-vortex structures (swirl and tumble) during the inlet process. A comparative study of the most commonly employed tumble benches along with in-house design was performed, the last showing some advantages with respect to the others. The outcomes from the simulations were in agreement with experimental results. Mainly, the tumble generation rate was in general proportional to the valve lift. However, tumble was reduced drastically at medium valve lift due to a change in the vortex pattern. A stagnation zone was observed between inlet valves. CFD calculations successfully captured this tumble-fall effect, which was related to characteristic changes in the vortex pattern downstream of the inlet valves at medium valve lift. This affects tumble production without affecting the mass flowrate efficiency. Finally, at high valve lifts the tumble production and the vortex pattern were recovered. The capability of the cylinder head to induce swirl, tumble, or combined swirl-tumble by modifying the valve timing or by introducing adjustable flow deflectors was evaluated using CFD. Several valve timing strategies were analysed: some of them produced significant swirl, but introduced high mass flowrate losses. On the other hand, adjustable flow deflectors were shown to be an interesting alternative to induce swirl-tumble at low load and to improve tumble at high load.