Combined effects of flow/spray interactions and EGR on combustion variability for a stratified DISI engine

This study investigates combustion variability of a stratified-charge direct-injection spark ignited (DISI) engine, operated with near-TDC injection of E70 fuel and a spark timing that occurs during the early part of the fuel injection. Using EGR, low engine-out NO x can be achieved, but at the expense of increased combustion variability at higher engine speeds. Initial motored tests at different speeds reveal that the in-cylinder gas flow becomes sufficiently strong at 2000rpm to cause significant cycle-to-cycle variations of the spray penetration. Hence, the fired tests focus on operation at 2000rpm with N2 dilution ([O2]=19% and 21%) to simulate EGR. In-cylinder flow, spray, and early-flame measurements are correlated to reveal their effect on the combustion variability. Results reveal two types of flow/spray-interactions that predict the likelihood of a partial burn. (1) Proper flow direction before injection with a more collapsed spray leads to high kinetic energy of the flow during injection, thus generating a rapid early burn, which ensures complete combustion, regardless of the EGR level. (2) Improper flow direction and less collapsed spray generate low flow energy during the early phase of combustion. For this second type of flow/spray-interaction, application of EGR results in a partial-burn frequency of 30%, whereas without EGR, early combustion is shown to be insensitive to flow variations. Flame-probability maps illustrate that the partial-burn cycles for operation with EGR have a weak flame development in that the flame does not develop uniformly and reliably from the spark plug. Without EGR, the flame development is more repeatable regardless of the type of flow/spray-interaction, at the expense of higher NO x emissions.