The current deterministic optimization design method ignores uncertainties in the material properties and potential machining error which could lead to unreliable or unstable designs. To improve the design efficiency and anti-jamming ability of a high-energy ultrasonic igniter, a Six Sigma multi-objective robustness optimization design method based on the response surface model and the design of the experiment has been proposed. In this paper, the initial structural dimensions of a high-energy ultrasonic igniter have been obtained by employing one-dimensional longitudinal vibration theory. The finite element simulation method of COMSOL Multiphysics software has been verified by the finite element simulation results of ANSYS Workbench software. The optimal igniter design has been achieved by using the proposed method, which is based on the finite element method, the Optimal Latin Hypercube Design method, Grey Relational Analysis, the response surface model, the non-dominated sorting genetic algorithm, and the mean value method. Considering the influence of manufacturing errors on the igniter’s performance, the Six Sigma method was used to optimize the robustness of the igniter. The Eigenfrequency analysis and the vibration velocity ratio calculation were conducted to verify the design’s effectiveness. The results reveal that the longitudinal resonant frequency of the deterministic optimization scheme and the robustness optimization scheme are closer to the design’s target frequency. The relative error is less than 0.1%. Compared with the deterministic optimization scheme, the vibration velocity ratio of the robustness optimization scheme is 2.8, which is about 15.7% higher than that of the deterministic optimization scheme, and the quality level of the design targets is raised to above Six Sigma. The proposed method can provide an efficient and accurate optimal design for developing a new special piezoelectric transducer.

By effective utilization of the dynamic mesh and coordinate transformation techniques, an ultrasonic horn is physically integrated in the chamber of an internal combustion engine. The consequences of multiple ultrasonic-fed strategies on the flow field, combustion process, and emission formation under the same working conditions are studied by numerical simulation. Based precisely on the bench test data, GT-Power and CONVERGE set up the original engine one-dimension (1d) and three-dimension (3d) simulation models. The chamber pressure and heat release rate of the 1d and 3d models under a full load condition of 3000 rmin(-1) were validated, and the maximum relative error is less than 5%, proving the accuracy of the model. By reforming the 3d numerical model, ultrasonics is added to the gasoline engine's combustion chamber. Six different ultrasonic-fed schemes with 20 kHz amplitude of 30-300 mu m are typically selected for in-depth research. The larger the amplitude, the stronger the turbulent kinetic energy (TKE), and the maximum TKE exceeds 46.6% at the ignition time. Stronger TKE can energetically encourage the generation of OH, O, and H radicals and improve the combustion reaction rate, and the peak pressure (P-MAX) is increased by 1.9 MPa compared with scheme No. However, NOX and HC emissions gradually increase, reaching a maximum of 32.4 and 43.8%, respectively, while CO and soot emissions decrease, reaching a maximum of 11.4 and 11%, respectively. Four groups of ultrasonic-fed schemes with an amplitude of 100 mu m and frequency of 20-50 kHz are scientifically studied. The findings indicated that the TKE level steadily increases as the frequency increases and the in-cylinder TKE increases by 16.4% at ignition time. The increase in ultrasonic frequency can promote the generation of active free radicals and meaningfully improve the combustion reaction rate to a certain extent. The P-MAX can be increased up to 1 MPa compared with scheme No. At the same time, the NOX, HC, and soot also increased considerably, reaching 31.8, 17.9, and 21.9%, respectively. The CO showed a downward trend but gradually slowed, with a maximum decline of 6.5% at 20 kHz. The above simulation analysis is based on the full load condition of 3000 rmin(-1), sufficiently proving that ultrasonics has a regulation effect on emissions and can achieve specific emissions through later optimization.