Methods for heat transfer and temperature field analysis of the insulated diesel, phase 3

Work during Phase 3 of a program aimed at developing a comprehensive heat transfer and thermal analysis methodology for design analysis of insulated diesel engines is described. The overall program addresses all the key heat transfer issues: (1) spatially and time-resolved convective and radiative in-cylinder heat transfer, (2) steady-state conduction in the overall structure, and (3) cyclical and load/speed temperature transients in the engine structure. These are all accounted for in a coupled way together with cycle thermodynamics. This methodology was developed during Phases 1 and 2. During Phase 3, an experimental program was carried out to obtain data on heat transfer under cooled and insulated engine conditions and also to generate a database to validate the developed methodology. A single cylinder Cummins diesel engine was instrumented for instantaneous total heat flux and heat radiation measurements. Data were acquired over a wide range of operating conditions in two engine configurations. One was a cooled baseline. The other included ceramic coated components (0.050 inches plasma sprayed zirconia)-piston, head and valves. The experiments showed that the insulated engine has a smaller heat flux than the cooled one. The model predictions were found to be in very good agreement with the data.