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Contents
Introduction
Methodology
Results
Summery
Introduction
In CFD modeling full vehicle is modeled considering front
bumper, grille, cabin, cargo, surrounding under hood and
under body components.
Introduction
Preliminary CFD Front End Cooling analysis is done on
existing commercial vehicle and correlated well with
field test results.
Intercooler
Radiator
CAD Cleanup
Using HyperMesh
Using TGrid
Using Fluent
No
Is met
the
targets?
Yes
Final Proto Test Verification
Wednesday, September 26, 2012
Radiator Tank
Radiator
Radiator Fan
Intercooler
Under-hood components
V1
N1
V2
N2
mc1
Tcin1
mc2
Tcin2
ma1
Tain1
ma2
Tain2
10
c1
c2
c3
c5
c6
h21
h31
h41
h51
h61
h12
h22
h32
h42
h52
h62
h13
h23
h33
h43
h53
h63
h14
h24
h34
h44
h54
h64
h15
h25
h35
h45
h55
h65
h16
h26
h36
h46
h56
h66
c1
c2
c3
c4
c5
c6
h21
h31
h41
h51
h61
h12
h22
h32
h42
h52
h62
h13
h23
h33
h43
h53
h63
h14
h24
h34
h44
h54
h64
h15
h25
h35
h45
h55
h65
h16
h26
h36
h46
h56
h66
Note : Owing to IPR policy the numerical values cloud not disclosed
Wednesday, September 26, 2012
11
Intercooler
Velocity contours (m/s)
Max
Max
Temperature contours ( C)
Temperature contours ( C)
Inlet Face
Inlet Face
Outlet Face
Outlet Face
Min
Min
CFD T = 76.5 C
CFD T = 5.5 C
12
Intercooler
Velocity contours (m/s)
Max
Max
Temperature contours ( C)
Temperature contours ( C)
Inlet Face
Inlet Face
Outlet Face
Outlet Face
Min
Min
CFD T = 76.5 C
CFD T = 5.5 C
13
Intercooler
Test
CFD
Radiator
Correlation
(%)
Test
CFD
Correlation
(%)
mc1
Tcin1
---
CFD Inputs
Flow Rate (kg/s)
Coolant/ Inlet Temp (C)
Charged air
side
Outlet Temp (C)
Temp Drop (C)
Heat Rejection (kW)
ma1
Tain1
ma1
Tain1
---
mc1
Tcin1
CFD Outcomes
Taout1Test
Taout1CFD
--
63.7
8.3
76.5
10
80
79.5
Tcout1Test Tcout1CFD
4.7
42.6
5.5
49.9
-83
82.8
14
Radiator
Max
Max
Min
Temperature contours ( C)
Temperature contours ( C)
Inlet Face
Inlet Face
Outlet Face
Outlet Face
Min
Min
CFD T = 52.5 C
Test Coolant T = 5 C
CFD T = 5.8 C
15
Radiator
Max
Max
Min
Temperature contours ( C)
Temperature contours ( C)
Inlet Face
Inlet Face
Outlet Face
Outlet Face
Min
Min
CFD T = 52.5 C
Test Coolant T = 5 C
CFD T = 5.8 C
16
Intercooler
Test
CFD
Radiator
Correlation
(%)
Test
CFD
Correlation
(%)
mc2
Tcin2
---
CFD Inputs
Flow Rate (kg/s)
Coolant/ Inlet Temp (C)
Charged air
side
Outlet Temp (C)
Temp Drop (C)
Heat Rejection (kW)
ma2
Tain2
ma2
Tain2
---
mc2
Tcin2
CFD Outcomes
Taout2Test
Taout2CFD
--
47.3
3.1
52.5
3.4
89
90.3
Tcout2Test Tcout2CFD
5
20.1
5.8
23.4
-84
83.6
17
Intercooler Radiator
-Fan Module (IRFM)
18
19
20
21
22
23
Max
Temperature contours ( C)
Inlet Face
Temperature contours ( C)
Inlet Face
Outlet Face
Max
Outlet Face
Max
Min
Min
CFD T = 70.1 C
2012 Automotive Simulation World Congress
CFD T = 78.5 C
24
Max
Temperature contours ( C)
Inlet Face
Temperature contours ( C)
Inlet Face
Outlet Face
Max
Outlet Face
Max
Min
Min
CFD T = 70.1 C
2012 Automotive Simulation World Congress
CFD T = 78.5 C
25
Radiator
Radiator
Max
Temperature contours ( C)
Temperature contours ( C)
Inlet Face
Max
Inlet Face
Outlet Face
Max
Outlet Face
Min
Min
CFD T = 5.9 C
Wednesday, September 26, 2012
CFD T = 6.4 C
26
Radiator
Radiator
Max
Temperature contours ( C)
Temperature contours ( C)
Inlet Face
Max
Inlet Face
Outlet Face
Max
Outlet Face
Min
Min
CFD T = 5.9 C
Wednesday, September 26, 2012
CFD T = 6.4 C
27
Summery
Correlation level between Field test and CFD simulation is
more than 80%
Hot air recirculation has been identified for new vehicle
under-hood compartment using validated CFD process
Under-hood compartment thermal flow field has been
improved by stooping hot air recirculation by introducing
sealing, thus improved :
12% Intercooler performance &
8.5% Radiator performance
Wednesday, September 26, 2012
28
THANK YOU !!
Contact:
Ashok Patidar
akpatidar@vecv.in
Wednesday, September 26, 2012
29