WAVE Knowledge Center

Building a WAVE Model: Gathering Data: Data Checklist

General Instructions
WAVE is a detailed multi-cylinder reciprocating engine simulation code. Its various sub-models require a
number of input parameters related to combustion chamber geometry, valve flow, manifold configuration,
etc. The data list below contains items that are either necessary or very helpful to successfully construct and
validate a WAVE engine model.
Suggested units are provided where appropriate. Other units may be used, but these should be indicated
clearly when supplied.
Finally, in order to validate the model with a high degree of precision, it is important to have as much
engine test data as possible. Test data can be provided as ASCII text files (preferred) or as printouts from
data acquisition systems.

A) Power Cylinder

Bore
Stroke
Connecting rod length, center to center
Piston pin offset (positive toward major thrust side)
TDC combustion chamber volume
Compression ratio
Number of cylinders
Firing order
Firing interval
Two or four stroke
Two-strokes: scavenging curve
Heat transfer area of combustion chamber: piston and head surfaces (expressed as
multiple of bore area)
Clearance height between top of piston and top of cylinder

B) Intake and Exhaust Geometry

_________ [mm]
_________ [mm]
_________ [mm]
_________ [mm]
_________ [m3]
_________
_________
_________
_________ [CA]
_________
_________
_________
_________ [mm]

Intake piping and manifold geometry

Exhaust piping and manifold geometry
EGR circuit geometry

_________
_________
_________

C) Valve/Port Data
Duplicate this information for each intake and exhaust valve:

Poppet Valves
Profile of lift vs. crank (or cam) angle - ASCII text file preferred
Valve/cam timing events
Dynamic valve data (e.g. valve event phase shift vs. engine rpm)
Tappet type (hydraulic/fixed)
Valve lash (hot)
Rocker arm ratio (if cam lift is prescribed)
Inner seat diameter (D)
Maximum valve lift
Valve flow data: flow coefficient (forward and reverse) vs. L/D

_________
_________
_________
_________
_________ [mm]
_________
_________ [mm]
_________ [mm]
_________

Piston Ported
Number of ports of the same type
Port geometry and precise location (drawing)
Profile of geometrical area (as an alternative to lift profile)
Port flow data: flow coefficient

_________
_________
_________
_________

Reed Valves
Effective mass
Effective spring constants
Effective damping constants
Maximum lift to stop
Spring pre-load distance
Pressure force area below reed
Profile of geometrical open area vs. lift
Profile of flow coefficient vs. lift

_________ [g]
_________ [N/m]
_________ [N*sec/m]
_________ [mm]
_________ [mm]
_________ [mm2]
_________
_________

EGR Valves
Maximum lift to stop
Cross-sectional area at maximum lift
Profile of pressure loss vs. flow
Profile of flow coefficient vs. lift

_________ [mm]
_________ [cm2]
_________
_________

D) Turbocharger
Compressor map showing operating points (map)
Compressor reference temperature
Compressor reference pressure
Compressor gas Cp
Specify total/total or total/static or static/static pressure ratio
Compressor speed:
connected to turbine number
geared to crankshaft: supply gear ratio
fixed speed
Compressor inlet diameter
Compressor exit diameter
Turbine map showing operating points
Turbine reference temperature
Turbine reference pressure
Turbine gas Cp
Turbine speed:
connected to compressor number
geared to crankshaft: supply gear ratio
fixed speed
Turbine inlet diameter
Turbine exit diameter
Mechanical efficiency
Moment of inertia of all rotating parts
Wastegate (if equipped)
Variable geometry turbine (if equipped): provide maps at different settings

_________
_________ [K]
_________ [bar]
_________ [J/kg/K]
_________
_________
_________
_________ [rpm]
_________ [cm]
_________ [cm]
_________ (map)
_________ [K]
_________ [bar]
_________ [J/kg/K]
_________
_________
_________ [rpm]
_________ [cm]
_________ [cm]
_________ [%]
_________ [kg*m2]
_________
_________

1. Building a WAVE Model: Gathering Data: Geometric Data

Gathering the geometric data can be the most time consuming part of model building. For an engine, the dimensions
of all the intake and exhaust systems, including the ports are required. It is necessary to model each part of these
systems with a high degree of accuracy but they are also the easiest part of the model to get right. Quite often not
enough time and thought is given to collecting the information needed to construct an accurate model. All areas of
the geometry are important, but specifically:

Inlet and exhaust manifold pipe lengths are extremely important especially for noise prediction work. They
also determine tuning points for engine performance curves.

Muffler and air cleaner volumes are extremely important especially for noise prediction work. They also
determine tuning points for engine performance curves.

Geometric data is usually found from engineering design drawings. In most cases this is sufficient. It is, however,
very useful to have access to the part that needs modeling, especially air cleaners, exhaust mufflers, and throttle
bodies. Exhaust mufflers are particularly useful if they have been cut open, allowing the internal geometry to be
viewed and compared to the drawings. Quite often the production item has some differences from the design
specification, which may or may not be important. A typical example: pipe edges that are shown on a drawing as a
clean cut may, in reality, have a sharp burr which intrudes into the pipe. This can be detrimental to flow and reduce
the effective diameter. Studying the real item also tends to give a better idea of how it performs and can give you a
good idea of how the flow will behave in certain parts of the system.

It is also useful to view intake manifolds so that the junction between the inlet runner and the main volume can be
modeled accurately. Throttle bodies and carburetors need to be carefully simulated for obvious
reasons. Carburetors, typically only used for small engine applications nowadays, usually come with a nominal
diameter specified by the manufacturer. However, quite often this nominal diameter is not the true effective
diameter that will need to be modeled; or, the nominal diameter refers to a certain section of the component rather
than the minimum diameter.

The component surface finish determines the flow losses due to wall friction. The material thermal properties are
used to determine the heat transfer when the structural conduction model is activated, otherwise simple heat
transfer coefficients are implemented.

As a general rule it is best to gather as much information and as many actual components as possible in order to
build the most accurate model possible.

2. Building a WAVE Model: Gathering Data: Engine Data

Engine data refers to all dimensions and characteristics associated with the actual engine itself. This includes the
cylinder head and inlet and exhaust ports. For the basic engine only minimal information is required:

Bore

Stroke

Connecting Rod length

Wrist Pin offset

Compression ratio

Firing order and timing

Mechanical Friction details

The ports require more detailed information which can only be collected from testing the ports on a steady state
flow rig. Typical information needed is:

Port flow coefficients taken from measured data

Valve diameters

Valve event timings

Valve lift or Cam profiles

It is often very useful to make molds of the ports. This allows you to measure the lengths and diameters more
accurately. This is particularly true of a 3/4/5 valve per cylinder engine when the multiple ports branch off from one
entry volume in the cylinder head. The modeling of this junction volume is very important.

If a complex combustion model is to be simulated, it is necessary to use a more detailed representation of an engine
cylinder (in WAVE this is called an IRIS cylinder). This type of cylinder can require more geometric information
relating to:

Shape of the cylinder head, ports, and combustion chamber

Position of valves in the combustion chamber and position of spark plug

Orientation and size of piston top shapes e.g. re-entrant bowls

Wall temperature characteristics and transfer coefficients

Piston ring and cylinder liner friction

3. Building a WAVE Model: Gathering Data: Operating Parameters

Operating Parameters refer to conditions at which the simulation will be run. Typical data required for an engine
are:

Inlet and exhaust wall temperatures

Engine operating speed

Fuel flow rate or fuel/air ratio

Piston, Head, and Liner average surface temperatures

Ambient conditions

Combustion data

These are the minimum conditions required to get the basic model running. It is necessary to have temperatures in
several locations in the exhaust system as this varies greatly and has a significant effect on predicted performance. If
a complete range of temperatures is not known, then it is recommended that WAVE structural conduction model is
activated. This module allows the exhaust ducts to reach an equilibrium temperature during the engine simulation. If
you do not have measured data available, a range of typical operating temperatures for various parts of the engine is
given at the end of this tutorial in the example model. In-cylinder temperatures are rarely measured but typical
values can be found. Combustion data should be measured from and correlated to a test engine.

Further test data is later required to perform the correlation of the model, including:

Dynamic intake and exhaust pressures

Cylinder pressure trace

Engine performance - IMEP, BMEP, volumetric efficiency, etc.