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Optimization of the Piston cooling oil jet using
Particleworks with modeFRONTIER
David Percival – EnginSoft UK
Rod Giles – Royal Enfield
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Royal Enfield - History
Longest established motorcycle company with continuous
production - since 1901
Redditch, UK 1901 - 1970
Chennai, India 1955 - present
Part of Eicher Group since 1994
Fastest growing motorcycle brand
30,000 units in 2005
720,000 units in 2018-19
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Background
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LS410
Himalayan
Royal Enfield is working on the LS410 engine for the
Himalayan bike
Adequate cooling of the Piston is essential in Engine
design
A poorly cooled Piston will warp over time affecting
the lifetime and reliability of the bike
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Problem
No way of calculating oil distribution or cooing effect
Rely on physical testing and hardness analysis
Inaccurate results – poor reliability
Increases time to Market
Decreases profits
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“How can we be sure the
piston will not overheat
and warp?”
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Initial process
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Initial Simulation
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CAD Model Build Simulation
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Camera’s motion
linked to Piston
motion
Results - Distribution
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Results – HTC Mapping
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Drainage Flowrate
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Drainage
holes
Draining
flowrate < 5%
of total flowrate
Probes
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Drainage Flowrate
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Average flowrate = 2.4% of
total flowrate
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Initial project - Conclusions
Using Particleworks we are able:
Calculate the HTC distribution of the oil jet
Calculate the flowrate of oil draining out of the piston to the
cylinder
This allows Royal Enfield to identify issues during the
design process
Saving time and money during physical testing and prototypes
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ADDED VALUE PROJECT
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Simulation Led Design
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Particleworks - modeFrontier A Particleworks API was created by EnginSoft
UK
The node introspects the Particleworks model
and finds all parameters we can vary
Parameters are dragged into the GUI and
modeFRONTIER modifies the model and
launches pre-processing, solver and post-
processing
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Simulation time reduction Mappings averaged over an entire cycle are
identical throughout simulation
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Averaged from 0.2-0.24s
(8 cycles)
Averaged from 0.2-0.208s (1
cycle)
Averaged from 0.08-0.016s
(1 cycle)
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Simulation time reduction Mappings averaged over an entire cycle are
identical throughout simulation
Flowrate though drainage holes is uniform
throughout simulation
Hence we are able to shorten the length of
the simulation to only 2 cycles (0.016s)
Simulation time can be reduced to 15-20
minutes
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Design Modifications
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-15° ≤ x Rotation ≤ 15°
-15° ≤ z Rotation ≤ 15°
1.2mm ≤ Nozzle diameter ≤ 2mm
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Workflow
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Local
Local
Cluster
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Results
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Rot X Rot Z Dia Avg HTC Num > 0 Flowrate
-6.1° -8.1° 1.906 826.27 658581 4%
Rot X Rot Z Dia Avg HTC Num > 0 Flowrate
-9.8° -15° 1.953 827.59 637548 2.6%
Rot X Rot Z Dia Avg HTC Num > 0 Flowrate
0° 0° 1.2 812.93 644866 2.4%
+1.80%
+2.13% +1.64%
-1.13%
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Ongoing work
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THANK YOU FOR YOUR ATTENTION
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