Advancing Internal Combustion Engines and Fuel Innovation: A Modular Approach to 3D Virtual Prototyping for a Carbon-Neutral Future

The upcoming automotive emission regulations require a rapid transition to near-zero emission vehicles, making it increasingly necessary to understand which type of carbon-neutral fuel best suits each internal combustion engine (ICE) application and vice versa. Given the high costs associated with the development of ICE layouts, components, and fuels, leveraging 3D-CFD simulations assumes an essential role as a screening tool preceding the prototyping phase. Intending to reduce computational time while extending the simulated domain to the entire engine (including a 0D or 3D turbocharger model), FKFS devised QuickSim, an innovative 3D-CFD tool for virtual engine development. Thanks to a combination of in-house numerical models for injectors, fuels, and combustion processes, this 3D-CFD software meets the requirements of a rapid and pragmatic virtual approach to drive the industrial evolution of future engines. This paper presents QuickSim as the cornerstone of a robust methodology for the simulation of a comprehensive engine domain, showcasing its efficacy in designing and optimizing engine layouts, characterizing individual components, and exploring fuel solutions to optimize combustion efficiency and emission reduction. The effectiveness of this approach was proved through several examples drawn from production and motorsports engine applications. Here, the impact of several fuels (hydrogen, methanol, synthetic, and biofuels) on different engine geometries was analyzed in conjunction with different injection and ignition systems, including active and passive pre-chambers. These preliminary studies highlight the modularity of QuickSim, enabling the systematic exploration of optimal fuel and engine layout combinations to maximize the stated efficiency.