Fuel Injectors and Spray CFD Simulation

FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization

CFD software such as MSC Cradle, AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge is well equipped to simulate fuel injectors and spray processes including liquid atomization, drop breakup, collision and coalescence, turbulent dispersion, spray cavitation, drop-wall interaction, and drop evaporation. With combination of a one-dimensional model typically represents the complete injection system from the fuel tank to the injector, 3D CFD Solver focuses on the three-dimensional calculation of the fluid flow inside the injection nozzle.

Wide array of fuel injection simulation methodology, and robust and well-validated physical models allow us for accurate and computationally efficient simulation of these complex physical processes. In applications such as internal combustion engines, the fuel spray initiates, propagates, and dissipates very quickly on a very small spatial scale.
The combustion process can be strongly affected by the exact nature of the fuel spray: droplet velocity, size, distribution, and physical attributes and for dynamically capture the important physics of the injection process, we need a high-density grid around the spray.
Enteknograte engineering team use advanced CFD tools for simulation and analysis of the injection of liquid fuel via physical models for blob injection, injection distribution, variable rate-shape, discharge coefficient, and hollow cone and solid cone sprays and simulating the mixing and evaporation of multi-component fuel sprays.
Analyses of Spray Air Nozzle and Spray Combustion multiphase simulation msc cradle fluent star-ccm+

Spray and Turbulence

Accurate spray and turbulence modeling is critical for predictive diesel and gasoline combustion simulations. In order to obtain results that are as realistic as possible, we use a wide variety of spray and turbulence modeling such as Reynolds-Averaged Navier-Stokes (RANS) and Large Eddy Simulation (LES) turbulence models. 

For spray, simulate injection, breakup, vaporization, and other spray-related processes with detail are available. We can perform simulations that are dual fuel or multi-fuel and diesel and gasoline are not the only fuels that we can simulate. 

Becasue of deep concern to engine manufacturers are the constantly evolving emissions regulations, To help meet these regulations, we simulate soot and NOx via its detailed chemistry. Soot emissions from gas turbine combustors are increasingly becoming a critical design factor as new particulate matter emissions regulations.

Injection Nozzle Development CFD AVL Ansys Fluent MSC 2

CFD Based Injection Nozzle Development

This simulation capabilities enable virtual design of: Reduce cavitation and avoid erosion in injection nozzles Achieve higher engine-out performance and lower engine-out emissions Performance Counts. In an early engine design stage, fuel injection details, such as needle lift and inlet pressure level, are not known. Thus, a virtual prototyping environment, consisting of 1D and 3D fuel injection simulations is extremely valuable.

Injection Nozzle Development CFD AVL Ansys Fluent MSC


We pride ourselves on empowering each client to overcome the challenges of their most demanding projects.

By using Accurate reaction mechanisms that representing every class of reaction important for combustion analysis and combination of advanced computational fluid dynamics (CFD) combustion simulation tools such as Kiva, Ansys Fluent, Ansys Forte, AVL Fire, Converge CFD, Siemens Star-ccm+ , MSC Cradle and System Modeling software such as Matlab Simulink and GT-Suite enable Enteknograte engineering team to reduce chemistry analysis time by orders of magnitude, virtually eliminating the bottleneck that chemistry integration produces during the simulation process.
Hexagon MSC Software© CoBrand RGB PRIMARY Logo

Using Simulation to Optimize Reacting Flows and Combustion

From automobile engines to gas turbine generators, reacting flow and combustion is often the key to energy efficiency, emissions, lifespan, product yield, and other performance parameters. Simulation help look deeper into reacting flow and combustion issues to understand the complex chemical reactions, fluid flow, heat transfer, electrical performance, and other factors that determine the performance of your product. Simulation enables our engineers to evaluate more design alternatives more thoroughly than traditional prototype-based design and development methods.


Gas Turbine Combustion CFD Simulation: Detailed Chemistry

AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge
Gas turbine combustion can be a challenge to achieve accurate and reliable CFD simulation results. Computational efficiency requires appropriate mesh resolution and turbulence, spray, combustion, and emissions models that provide an appropriate level of detail. With using advanced and specilized CFD tools such as AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge, Enteknograte engineers can accurately predict important kinetically limited gas turbine phenomena such as ignition, flashback, and lean blow off. In addition, we can investigate the combined effects of chemistry and turbulence and optimize combustor performance parameters.

Fuel Injectors and Spray CFD Simulation

CFD software such as MSC Cradle, AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge is well equipped to simulate fuel injectors and spray processes including liquid atomization, drop breakup, collision and coalescence, turbulent dispersion, spray cavitation, drop-wall interaction, and drop evaporation.

Spray, Combustion, Emissions, Shaft and Gear Systems, Acoustic Enclosures

Gas turbine combustion is a complex process, and it can be a challenge to achieve accurate and reliable Finite Element and CFD simulation results at a reasonable computational cost. Computational efficiency requires appropriate mesh resolution and turbulence, spray, combustion, and emissions models in CFD tools such as AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge that provide an appropriate level of detail. It needs adavnced combination of Finite Element and Acoustic Solvers to capture real-world vibration and structural performance with FEA tools such as Abaqus, Ansys and LS-Dyna and Acoustic solver such as MSC Actran and ESI VA-ONE.

CFD Simulation of Reacting Flows and Combustion

Engine & Gas Turbine, Fuel Injector & Spray, Exhaust Aftertreatment with Detailed Chemistry
Knowledge of the underlying combustion chemistry and physics enables designers of gas turbines, boilers and internal combustion engines to increase energy efficiency and fuel flexibility, while reducing emissions. Combustion System couples multiphysics simulations incorporating accurate physical models with an advanced chemistry solver to provide a complete end-to-end combustion chemistry simulation capability to optimize products that involve reacting flow.

CFD Simulation of Engine Exhaust Aftertreatment

Aftertreatment systems are a critical component to ensure emissions from engines and power generation equipment comply with environmental standards. CFD (computational fluid dynamics) simulations can be used as part of a rapid prototyping process to design systems that reduce NOx, CO, and particulate matter emissions with minimal efficiency and maintenance costs. Two of the main challenges in aftertreatment system design are maximizing the uniformity of flows upstream of catalysts and eliminating areas at risk for urea deposition.

1D/3D Coupled Simulation and Co-Simulation: Detailed Chemistry & Multiphase Flow Modeling with 1D Modeling

Enteknograte engineering team use advantage of CFD solver’s detailed chemistry, multiphase flow modeling, and other powerful features in coupling and co-simulation of CFD (Siemens Star-ccm+, AVL Fire, Ansys Fluent, Converge), 1D systems softwares (Matlab simulink, GT-Suite, Ricardo Wave allowing 1D/3D-coupled analyses to be performed effortlessly) and FEA software (Abaqus, Ansys, Nastran) for engine cylinder coupling, exhaust aftertreatment coupling, and fluid-structure interaction coupling simulation.

Integrated Artificial Intelligence (AI) & Machine Learning - Deep Learning with CFD & FEA Simulation

Machine learning is a method of data analysis that automates analytical model building. It is a branch of Artificial Intelligence based on the idea that systems can learn from data, identify patterns and make decisions with minimal human intervention. With Artificial Intelligence (AI) applications in CAE, that is Mechanical Engineering and FEA and CFD Simulations as design tools, our CAE engineers evaluate the possible changes (and limits) coming from Machine learning, whether Deep Learning (DL), or Support vector machine (SVM) or even Genetic algorithms to specify definitive influence in some optimization problems and the solution of complex systems.

Heat Transfer and Thermal Analysis: Fluid-Structure Interaction with Coupled CFD and Finite Element Based Simulation

We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort. Our Finite Element (LS-Dyna, Ansys, Abaqus) and CFD simulation (Siemens Start-ccm+, Ansys Fluent , Ansys CFX and OpenFoam) for heat transfer analysis, thermal management, and virtual test process can save time and money in the design and development process, while also improving the thermal comfort and overall quality of the final product.

Acoustics and Vibration: FEA and CFD for AeroAcoustics, VibroAcoustics and NVH Analysis

Noise and vibration analysis is becoming increasingly important in virtually every industry. The need to reduce noise and vibration can arise because of government legislation, new lightweight constructions, use of lower cost materials, fatigue failure or increased competitive pressure. With deep knowledge in FEA, CFD and Acoustic simulation, advanced Acoustic solvers and numerical methods used by Enteknograte engineers to solve acoustics, vibro-acoustics, and aero-acoustics problems in automotive manufacturers and suppliers, aerospace companies, shipbuilding industries and consumer product manufacturers.

Aerodynamics Simulation: Coupling CFD with MBD, FEA and 1D-System Simulation

Aerodynamics studies can cover the full speed range of low speed, transonic, supersonic and hypersonic flows as well as turbulence and flow control. System properties such as mass flow rates and pressure drops and fluid dynamic forces such as lift, drag and pitching moment can be readily calculated in addition to the wake effects. This data can be used directly for design purposes or as in input to a detailed stress analysis. Aerodynamics CFD simulation with sophisticated tools such as MSC Cradle, Ansys Fluent and Siemens Star-ccm+ allows the steady-state and transient aerodynamics of heating ventilation & air conditioning (HVAC) systems, vehicles, aircraft, structures, wings and rotors to be computed with extremely high levels of accuracy.

Finite Element Analysis of Durability and Fatigue Life

Vibration Fatigue, Creep, Welded Structures Fatigue, Elastomer and Composite Fatigue with Ansys Ncode, Simulia FE-Safe, MSC CAEFatigue, FEMFAT
Durability often dominates development agendas, and empirical evaluation is by its nature time-consuming and costly. Simulation provides a strategic approach to managing risk and cost by enabling design concepts or design changes to be studied before investment in physical evaluation. The industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life and FEMFAT used to calculate fatigue life of multiaxial, welds, short-fibre composite, vibration, crack growth, thermo-mechanical fatigue.

Multi-Phase Flows CFD Analysis

Multi-Phases flows involve combinations of solids, liquids and gases which interact. Computational Fluid Dynamics (CFD) is used to accurately predict the simultaneous interaction of more than one combination of phases that can be gases, solids or fluids. Typical applications involve sprays, solid particulate transport, boiling, cavitation, state-changes, free surface flows, dispersed multiphase flows, buoyancy problems and mixed species flows. For example, the risks from flow or process-induced vibration excitation of pipework are widely acknowledged in onshore process plants, offshore topsides and subsea facilities.