Foto del docente

Stefania Falfari

Associate Professor

Department of Industrial Engineering

Academic discipline: IIND-06/A Fluid Machinery

Research

Keywords: Turbulence Tumble Fuel Injection Pumps Ignition Water injection Combustion Laminar flame speed Internal combustion engines 3D-CFD simulations Chemical kinetics Fuel cell Energy analysis of possible future scenarios of modern powertrains SOFC Hydrogen: direct injection Hydrogen: combustion Simulation of cardiovascular system Fluid-Solid Interaction FSI (lumen-blood) Hemodynamic simulation in OpenFoam

The research activity has been developed in different areas:

1. One-dimensional modeling of:

a. pneumatic and hydraulic systems for industrial and automotive applications: Common Rail injection systems, hydraulic pumps, motorcycle forks.

b. One-dimensional modeling of gasoline and alternative fuel (including hydrogen) engines for the study of the combustion process, including cold start.

2. Three-dimensional fluid dynamic modeling of:

a. combustion process for high-performance gasoline engines, with particular reference to ignition;

b. study of highly turbulent flows;

c. study of the formation of organized motions of the charge in the cylinder (Tumble).

d. Analysis of water injection in modern GDI engines.

e. Modeling of the KNOCK process in modern GDI and PFI engines.

f. Direct hydrogen injection: highly under-expanded jets.

3. 0D/3D CFD modeling of the cardiovascular system. Modeling with non-Newtonian fluid (blood) and for laminar/turbulent flow, with lumen-blood interaction (fluid-structure interaction) if relevant.

 1. Mono-dimensional modelling: The first branch of research concerns the development of models for simulating high pressure and fast-actuation solenoid injection systems equipping Common Rail Diesel engines. In particular she developed and validated an experimental methodology of study based on the integrated use of  both mono-dimensional and three-dimensional simulations for obtaining a completely predictive injection system model in collaboration with Magneti Marelli Bologna. Since 2006 she has contracts with industries like FAR, VM-Motori and PAIOLI for mono-dimensional simulation of pneumatic and hydraulic circuits. Last of all she collaborates with Bucher Hydraulics for modelling hydraulic external gear pumps characterized by unitary transmission ratio: in this branch it is of interest the study of  the pressure trend in the inter-teeth volumes related to the pump geometry, the teeth number and the teeth shape for limiting their noise. Finally a new research branch concerns the study of the 'cold start-up' for internal combustion engines fed by pure ethanol.

2. Three-dimensional modelling: In this context, the research activity has focused on the study and modeling of the combustion process in high-performance gasoline engines with the KIVA-3 code developed with the implementation of numerous models at the University of Bologna. In particular, the problems related to ignition have been analyzed and a model capable of simulating this process has been developed. This is a critical point in 3D CFD modeling because it is necessary to correctly predict the operation of the ignition system in gasoline engines. In particular, the criterion used for the flame deposition and the subsequent initialization of the actual combustion phase are critical. Obviously, an accurate modeling of this process would require the solution of time-steps and lengths much smaller than those typical of RANS CFD simulations, which would increase the calculation times too much. The model developed during this research activity is a one-dimensional ignition model, which is then coupled to the 3D CFD model, and which takes into account the effects of convection, turbulence and mixture index on the development of the flame kernel and then on the combustion of premixed flames.

Subsequently, the research activity focused on the analysis of flows in internal combustion engines, with particular attention to the formation of organized charge motions. In fact, the continuous demand for low environmental impact engines and therefore low consumption and high efficiency, implies the need for rapid combustion and reduced cyclic variability. In PFI engines, which are still the most used, it is absolutely necessary to obtain an organized charge motion at the time of filling to increase efficiency. In particular, the formation of a coherent tumble vortex with dimensions comparable to the piston stroke tends to promote the formation of a high level of turbulence at the end of the compression stroke, which accelerates the combustion process and allows the adoption of even “lean-burn” strategies, which are otherwise characterized by high cyclic variability due to combustion instability. In particular, for motorcycle or scooter applications, the tumble motion is considered even more important to increase engine efficiency because the reduced weight and the size limits, as well as the cost, limit in this field the adoption of systems that are instead widely used in the automotive field. A study is currently underway aimed at verifying the influence that some geometric and operating parameters have on the generation of the tumble motion during the intake phase, as well as on the production of turbulence during the compression phase, considering however also the importance of the cylinder filling and therefore not neglecting this aspect compared to the rest.

Finally, the research focused on the 3D modeling of highly under-expanded jets for the correct prediction of the behavior of hydrogen injected directly into the combustion chamber.

The reference CFD code for simulations is AVL Fire.

She conducted her research activity in collaboration with: VM Motori, Magneti Marelli Bologna, Ferrari, PIAGGIO, FAR, PAIOLI, BUCHER HYDRAULICS.

3. 0D / 3D CFD modeling of the cardiovascular system. Modeling of the hemodynamics of the cardiovascular system with a zero-D approach (Phyton) and with a 3D approach (OpenFoam code), considering blood as a NON-NEWTONIAN fluid and also modeling the LUMEN-BLOOD INTERACTION (fluid-structure interaction) where applicable. The reference code for 3D simulations is OpenFoam.

Finally, in recent years, research activity has focused on:

1. Dynamic analysis of intake and exhaust processes in gasoline engines, aimed at maximizing filling and minimizing pumping work.

2. Study of the combustion process for gasoline engines, with particular attention to predictive modeling of the onset of the knocking process.

3. CFD analysis of water injection in latest-generation GDI engines, aimed at containing the charge temperature at IVC and TDC.

4. CFD analysis of modern Miller/Atkinson cycles applied to modern turbocharged GDI engines.

5. Thermal analysis of a methanator.

6. Fluid-thermodynamic study of latest-generation 'SACI' type gasoline engines.

7. Analysis of the orientation during assembly of a PFI injector to minimize cold polluting emissions for motorcycle applications.

8. Study of GCI combustion and the related injection process.

9. Chemical kinetic simulations aimed at defining the laminar flame velocity and the auto-ignition time for mixtures of different fuels (for example hydrogen, methane, ammonia) in operating conditions of interest for motorsports.

10. Analysis of the evaporative process of lubricating oil in latest generation internal combustion engines.

11. Well-to-Miles energy analysis of modern powertrains.

12. Use of hydrogen in modern combustion engines.

13. 1D modeling of the fuel cell hybrid powertrain.

14. Study of the NOTIONAL NOZZLE in highly under-expanded gaseous jets (hydrogen).

15. 0D model of emptying of a hydrogen tank at 700 bar.

16. CFD analysis of the TPRD for applications with hydrogen stored at 700 bar.

17. "Explosion" analysis of hydrogen jets exiting a TPRD.

18. Development of an internal combustion engine coupled to a solid fuel cell (SOFC) for naval applications (SOFFHICE Project, Prot. P2022K3TMP, funded by the European Union – NextGenerationEU, under the National Recovery and Resilience Plan PNRR, Mission 4 Component 2 Investment 1.1 – National Program of Research (PNR) and Research Projects of Relevant National Interest (PRIN), Call for tender n. 1409 of 14-9-2022 of University and Research Ministry MUR):

- from the SOFC exhaust the engine receives a defined flow of Anod Off-Gases (AOGs), containing small percentages of hydrogen, carbon monoxide and carbon dioxide,

- definition of the chemical characteristics of the fuel used (methane, ammonia), with and without hydrogen (contained in the AOGs and which can act as an accelerant for a very lean combustion),

- optimization of the engine dimensions based on the available space and the performance related to the type of "trip", in terms of power but also of consumption containment (therefore maximization of efficiency),

- study of the engine geometry (with active pre-chamber) with CFD modeling,

- dynamic coupling of the model with a model of the SOFC.

19. Modeling of the hemodynamics of the cardiovascular system with a zero-D approach (Phyton) and with a 3D approach (OpenFoam code).