Prediction of cavitation and induced erosion inside a high-pressure fuel pump

The operation of a high-pressure, piston-plunger fuel pump oriented for use in the common rail circuit of modern diesel engines for providing fuel to the injectors is investigated in this study from a numerical perspective. Both the suction and pressurization phases of the pump stroke were simulated with the overall flow time being in the order of 12x10(-3)s. The topology of the cavitating flow within the pump configuration was captured through the use of an equation of state implemented in the framework of a barotropic, homogeneous equilibrium model. Cavitation was found to set in within the pressure chamber as early as 0.2x10(-3)s in the operating cycle, while the minimum liquid volume fraction detected was in the order of 60% during the second period of the valve opening. Increase in the in-cylinder pressure during the final stages of the pumping stroke leads to the collapse of the previously arisen cavitation structures and three layout locations, namely, the piston edge, the valve and valve-seat region and the outlet orifice, were identified as vulnerable to cavitation-induced erosion through the use of cavitation aggressiveness indicators.