A Physics-based mean value model that predicts engine combustion, heat transfer, gas exchange, and friction loss has been developed. The model is developed starting from the thermodynamic principles of an ideal gas standard limited pressure cycle concept. The idealized assumptions that are typically used in a limited pressure cycle concept are relieved to enhance the fidelity of the model by introducing variables that account for the in-cylinder heat transfer and the combustion characteristics that change under varying EGR rate as well as the engine speed and load while minimal number of empirical correlations are used to ensure the compactness and flexibility of the physics-based mean value model. The model is calibrated and validated with the simulation results from a detailed GT-Power® engine model previously calibrated with experimental results from a Ford 6.7 liter Diesel engine. The comparison shows good agreement between the results from the mean value model and the GT-Power® model. The mean value model developed in this study is a flexible simulation tool that provides excellent computational efficiency without sacrificing critical physical details of the Diesel combustion process required by the control design development.

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