Numerical investigation of cavitation erosion in high-pressure fuel injector in the presence of surface deviations

This study investigates cavitation-induced erosion in high-pressure fuel injectors using numerical simulations, focusing on the effects of surface deviations, turbulence modeling, and a refined approach for the erosion assessment. The proposed erosion model combines advanced erosion indicators to enhance predictive accuracy while addressing limitations in existing methodologies. Cavitation dynamics are simulated with the modified Zwart–Gerber–Belamri model, employing Reynolds-averaged Navier–Stokes (RANS) and Large Eddy Simulation (LES) approaches. Numerical results for a high-lift needle position are validated against experimental data, providing insights into erosion behavior in industrial heavy-duty injectors. Both Computer-Aided Design (CAD) and Tomography Scan (TS) models are used to evaluate the impact of surface deviations on erosion patterns. Results reveal that incorporating surface deviations reduces the vapor volume and alters the erosion patterns. LES simulations exhibit enhanced sensitivity to the surface deviations, capturing finer turbulence structures and local pressure fluctuations, whereas RANS provides reasonable accuracy with lower computational cost. • Cavitation erosion risk assessment using two algorithms with four indicator quantities. • Surface deviations impact erosion patterns in injector geometries. • LES model captures detailed cavitation dynamics. • RANS may provide efficient, cost-effective cavitation erosion risk assessment.