Injection Nozzle Development

AVL FIRE™ M offers indispensable capabilities when it comes to the development and optimization of injection nozzles. While a one-dimensional AVL BOOST™ Hydsim model typically represents the complete injection system from the fuel tank to the injector, FIRE focuses on the three-dimensional calculation of the fluid flow inside the injection nozzle.

Unrivalled simulation capabilities enable virtual design verification to:

  • Reduce cavitation and avoid erosion in injection nozzles
  • Prevent nozzle coking
  • 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.

While AVL BOOST Hydsim provides the information about longitudinal and radial needle displacements as well as pressure levels at injection nozzle inlet, AVL FIRE accurately predicts the fuel conditions inside the nozzle and its impact on break-up, ignition and combustion in the IC engines combustion chamber.

To get the maximum benefit out of both tools, BOOST and FIRE models can be coupled in a co-simulation, with FIRE providing pressure forces on the injector needle and BOOST computing longitudinal and radial needle motion based on this information. This allows to calculate discharge rates more accurately and to precisely predict cavitation and erosion.