Experimental investigations into the effects of string cavitation on diesel nozzle internal flow and near field spray dynamics under different injection control strategies

•Visualization experiments of the real-size transparent nozzle were performed.•The real pressure fluctuation for the nozzle inlet was obtained.•The flow cavitation and near-field spray under different control strategies was obtained.•The shoe-shaped increasing trend of spray was found Out.•The influence of lift throttling, residual bubbles and pressure fluctuation was studied. On the test bench of the high-pressure common rail injection system with a high-speed camera, the visualization experiments of real-size tapered hole nozzle of the diesel engine were performed to obtain needle valve lift, string cavitation in the sac chamber and nozzle hole, residual bubbles and near-field spray characteristic. And a high-pressure sensor was utilized to measure the real pressure fluctuation for the nozzle inlet. On the basis, under different control strategies, the comprehensive effects of needle valve throttling and pressure fluctuation for nozzle inlet on the internal flow and near-field spray characteristic under the multiple injections were studied. Research indicated that the spray cone angle and the spray area ratio in the main injection stage shows a boot-shaped increasing trend of slowness and then abruptness. In the development stage, the spray cone angle fluctuates in a little range (20°-30°); In the saturation phase, the spray cone angle fully develops and the fluctuation is relatively stable (40°-50°). As the throttling position shifts, there is an obvious string cavitation process, and the spray cone angle increases suddenly. In the process of pre-injection and post-injection, needle valve and valve seat throttling and lift instability cause fuel pressure fluctuation in the control chamber and sac, which is the main immediate cause of the fluctuation of low fuel injection quantity. Besides, the interval time between multiple injections, on the one hand, affects the state of residual bubbles in the nozzle before the next injection beginning, on the other hand, it also affects the stability of the inlet pressure at this time. The flow transition in the low-lift zone and the cavitation changing in the high-lift stable zone also cause transformation in the form of pressure fluctuation.