Dynamics optimization of coupling atomization process in an injector achieved by novel micro laser powder bed fusion

This study employed large eddy simulation and a volume-of-fluid with discrete phase model to evaluate a swirl fuel injector's atomization performance. Addressing non-uniform atomization at low flow rates, the study optimized a swirl injector structure based on additive manufacturing advantages during re-modeling. Computational analysis revealed that vortex downstream and capillary bubbles caused non-uniformity in the prototype injector, mitigated by the optimized injector's three-dimensional flow channel. Comparative analysis showed similar parameters between the optimized and prototype injectors, except for significant improvement in circumferential uniformity at low flow rates (from 41.48% to 14.69%). The optimized injector's swirl structure, produced via micro laser powder bed fusion, exhibited precise dimensions and minimal surface roughness. Validation experiments without air inflow confirmed the computational results' reliability, with a minor discrepancy in circumferential uniformity (2.98%) and atomization cone angle (2.3°) for the prototype swirl structure. At low flow rates, the optimized structure showcased reduced circumferential non-uniformity (from 42.31% to 28.76%), underscoring its benefits. This interdisciplinary investigation underscores additive manufacturing's application in structural optimization and manufacturing.