Development and validation of a free-piston engine generator numerical model

•Detailed numerical model of free-piston engine generator is presented.•Sub models for both starting process and steady operation are derived.•Simulation results show good agreement with prototype test data.•Engine performance with different starting motor force and varied loads are simulated.•The efficiency of the prototype is estimated to be 31.5% at a power output of 4kW under full load. This paper focuses on the numerical modelling of a spark ignited free-piston engine generator and the model validation with test results. Detailed sub-models for both starting process and steady operation were derived. The compression and expansion processes were not regarded as ideal gas isentropic processes; both heat transfer and air leakage were taken into consideration. The simulation results show good agreement with the prototype test data for both the starting process and steady operation. During the starting process, the difference of the in-cylinder gas pressure can be controlled within 1bar for every running cycle. For the steady operation process, the difference was less than 5% and the areas enclosed on the pressure–volume diagram were similar, indicating that the power produced by the engine and the engine efficiency could be predicted by this model. Based on this model, the starting process with different starting motor forces and the combustion process with various throttle openings were simulated. The engine performance during stable operation at 100% engine load was predicted, and the efficiency of the prototype was estimated to be 31.5% at power output of 4kW.