Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Raj Ranganathan
October 29-30, 2012
Senior Vice President Technical
Showatech, Inc.
Presentation Roadmap
1.
Introduction
a.
b.
2.
d.
e.
f.
g.
h.
Background
Benchmark in-cylinder measurements
Interaction of heat transfer with
combustion
Zero and multi-dimensional modeling
Standard and modified wall functions
Low Reynolds Number Model
Heat Transfer Coefficients
Validation with measurements
5.
Overview
Piston, liner, head and valve temperatures
Bay-to-bay breathing
Engine cooling system considerations
Engine lubrication system considerations
6.
3.
4.
Turbocharged SI Engine
Bozza et al, 3D-1D Analysis of the Turbulent Flow Field, Burning Speed and Knock Occurrence in a
Turbocharged SI engine, SAE 07NAPLES-69, 2007
Engine Components
Inline 4 Cylinder SI Engine with Dual Overhead Cams
http://www.carbibles.com/fuel_engine_bible.html
1. Intake
2. Compression
3. Power (Expansion)
4. Exhaust
http://en.wikipedia.org/wiki/File:4StrokeEngine_Ortho_3D_Small.gif
Engine Components
Typical Four Stroke Single Cylinder Engine
Spark Plug
Exhaust Camshaft
Intake Camshaft
Valves
Water Jacket
Piston
Connecting Rod
Crankshaft
http://en.wikipedia.org/wiki/Reciprocating_engine
http://en.wikipedia.org/wiki/Internal_combustion_engine
http://en.wikipedia.org/wiki/File:4StrokeEngine_Ortho_3D_Small.gif
Exhaust Components
Passenger Car SI Engine Exhaust System
http://carline.com.au/more-about-exhausts.html
10
Exhaust System
Key Components
http://www.quickhonda.net/exhaust.htm#Analysis%20of%20the%20Exhaust%20System%20in
%20an%20Average%20Car
Exhaust Flow in an Automobile, Alvin Teo
11
Exhaust System
Details
http://www.sundevilauto.com/tag/auto-diagrams
12
Heat Transfer
Broad Definition
What is thermodynamics?
13
From Peter, ORourke, Dan Haworth, Raj Ranganathan, Computational Fluid Dynamics, ASM
Handbook, Volume 20: Materials
14
Simulation:
Experiment:
15
CFD:
Three-Dimensional
Governing partial differential equations: mass, momentum, energy and species
Less Empirical (example turbulence modeling)
Spatial Resolution Millions of Cells
Network:
One-Dimensional
Algebraic balance expressions
More Empirical
Limited Spatial resolution Hundreds of Cells
Computational Domain System level (example lubrication system)
Analysis Cost Low
16
Zero-Dimensional
More Empirical
Garbage-in garbage-out
17
Overview of CFD
Method of Solution
Using commercial software:
Solve continuity, momentum, energy and species conservation equations
The majority of flows are turbulent Equations for turbulence
Define computational domain
Mesh the domain
Numerically solve the problem on a computer
Post process results
Ensure cell quality skewness, volume growth etc.
Prism layers at the wall
Grid independent solutions
Hexahedral mesh higher accuracy, labor intensive
Tetrahedral mesh less labor intensive (faster mesh creation), accuracy?
1.
2.
3.
Ferziger, J. H. and Peric, M., Computational Methods for Fluid Dynamics, Springer, 1997.
Patankar, S. V., Numerical Heat Transfer and Fluid Flow, Hemisphere, 1980.
ORourke, P. J., Haworth, D. C. and Ranganathan, R., Computational fluid dynamics, ASM Handbook, vol 20:
Materials selection and design, 1998.
18
Overview of CFD
Navier Stokes Equations
The conservation equations of momentum, energy and species possess a common
form and can be cast in a general form as shown (using the Cartesian tensor notation):
u j S
t
x j
x j x j
Continuity Equation:
dependent variable: T, C and uj
uj velocity field
diffusion coefficient (kinematic viscosity, thermal diffusivity or mass diffusivity)
S remaining terms assembled into source term
Ferziger, J. H. and Peric, M., Computational Methods for Fluid Dynamics, Springer, 1997.
Patankar, S. V., Numerical Heat Transfer and Fluid Flow, Hemisphere, 1980.
ORourke, P. J., Haworth, D. C. and Ranganathan, R., Computational fluid dynamics, ASM Handbook, vol 20:
Materials selection and design, 1998.
19
Simplified 1-D
Energy Equation
cp T
t
Inertia
c T v
p
Advection
T
dP
qcomb
t
y
y
dt
Diffusion
Source
20
Simplified 1-D
Energy Equation
cp T
t
c T v
p
T
dP
qcomb
t
y
y
dt
Velocity
1.
2.
3.
4.
5.
6.
Reactions
21
Simplified 1-D
Energy Equation
cp T
t
c T v
p
T
dP
qcomb
t
y
y
dt
Eddy conductivity
22
Boundary Layers
Turbulent Flow
Boundary conditions at a surface Formation of boundary layers in the region
between wall and the far-field.
The boundary layer consists of three sub-layers viscous, buffer and inertial
Viscous sub-layer adjacent to a surface in which molecular transport (of heat,
momentum and species) is dominant k >> kt
Inertial sub-layer in which turbulent eddy transport (of heat, momentum and species)
is dominant k << kt
Buffer Layer transition layer that separates the above two layers in which both
molecular and eddy transport are important O (k) ~ O(kt)
Modeling boundary layers accurately is a pre-requisite for accurate wall heat transfer
predictions
Simplified 1-D
Energy Equation
cp T
t
c T v
p
T
dP
qcomb
t
y
y
dt
Eddy conductivity
23
1.
24
Dimensionless Groups
Convection Heat Transfer
Br
U2
k T
St
hf L
Nu
Y
kf
1.
hf
V cp
Bi
Nu
Re Pr
hC LS
kS
25
Fluid Temperature
Heat Transfer
coefficient
FLUID
DOMAIN
SOLID
DOMAIN
Wall temperature
Courtesy Ricardo
26
q
f
s
f
Wall
s
h
f
Solid cell
Solid cell centre
f
f
, h
s
s
s
h f T f h sT s
T
h f hs
hf
q
T f T w
27
Solar
Visible
Infrared
Microwave
103
1011
102
1012
101
1013
X-rays
< 10-2
Ultraviolet
10-2 0.4
Visible
0.4 0.7
Infrared
0.7 1000
Thermal
0.1 100
Solar
0.1 3
Microwave
> 102
Ultraviolet
100
1014
10-1
1015
X-rays
10-2
1016
Wavelength
10-3
1017
Frequency s-1
Incropera, F. P. and Dewitt, D., Fundamentals of Heat and Mass Transfer, John Wiley, 1994.
28
Thermocouples
Basic Iron-Constantan Circuit
Overview
http://www.nphheaters.com/technical/thermo_letter.htm#measure
29
Fuel Efficiency
Emissions HC, CO
30
31
32
DI diesel engine
Flat Cylinder Head, Bowl in Piston
Eight Hole Nozzle Injector
2D Axi-symmetric Sector Mesh
Piston and Wall Heat fluxes
1. Kleeman, A. P., Gosman, A. D. And Binder, K. B., Heat Transfer in Diesel Engines: A CFD Evaluation
Study, The Fifth International Symposium on Diagnostics and Modeling of Combustion in Internal
Combustion Engines (COMODIA), July 1-4, Nagoya, Japan, 2001.
2. Kleeman, A. P., CFD Simulation of Advanced Diesel Engines, PhD thesis, 2001.
33
34
Surface Temperatures
Flame Arrival
Flame Arrival
35
Flame arrival
36
Piston
690 CA
Axis
740 CA
Liner
700 CA
750 CA
710 CA
760 CA
720 CA
730 CA
Courtesy CD-Adapco
Symmetry Plane
Engine Operating Point 1
Alkidas et al (1980-82)
37
Piston
690 CA
Axis
740 CA
Liner
700 CA
750 CA
710 CA
760 CA
720 CA
730 CA
Courtesy CD-Adapco
Symmetry Plane
Engine Operating Point 1
Alkidas et al (1980-82)
38
2500.0
2250.0
Location: HT-1
2000.0
1750.0
1500.0
1250.0
Flame Arrival
1000.0
750.0
~ 707 CA
500.0
250.0
0.0
690.00
720.00
750.00
780.00
810.00
Crank Angle
Courtesy CD-Adapco
39
Background
In-Cylinder Simulation Paths
40
Combustion Simulation
Zero-D and 3-D Models
Cylinder Pressure (bars) versus Crank Angle (degrees)
Bozza F., Fontana G, Galloni E and Torella E, 3D-1D Analysis of the Turbulent Flow Field, Burning
Speed and Knock Occurrence in a Turbocharged SI engine, SAE 07NAPLES-69, 2007.
41
No spatial variation
Under predicts HT
1. Kleeman, A. P., Gosman, A. D. And Binder, K. B., Heat Transfer in Diesel Engines: A CFD Evaluation
Study, The Fifth International Symposium on Diagnostics and Modeling of Combustion in Internal
Combustion Engines (COMODIA), July 1-4, Nagoya, Japan, 2001.
42
43
Simulation
Transient and Combustion Terms
SI Engine
Transient
Combustion
1. Han, Z. and Reitz, R. D., A Temperature Wall Function Formulation for Variable-Density
Turbulent Flows with Application to Engine Convective Heat Transfer Modeling, International
Journal of Heat and Mass Transfer, Vol. 40, No 3., pp. 613-625, 1997.
44
Momentum Equation
Viscous and Inertial Layers
Quasi-steady
u
t
t x , y
u u
x
Couette Flow
u v
y
dP
u
dx
y
y
u u (y)
u
u
u
v
x
y
Assume
v 0
dP t u
dx
y
y
Flat Plate BL
u constant
Properties
(P, T)
(T)
45
Momentum Equation
Closed Form Solution
Viscous Region
d
du
t
0
dy
dy
du
W
dy
Turbulent Region
f
f
t
Viscous Region
u y
Inertial Region
Log-law
y ym
log e E y
y ym
ym - intersection
Properties
46
Energy Equation
Viscous and Inertial Layers
Quasi-steady
cp T
t
t x , y
Tu
Tv
Quasi-steady
t x , y
T
dP
k kt
y
y
dt
Couette Flow
T T (y)
T
T
cp u
v
x
y
k kt T
y
y
Properties
(P, T)
(T)
Assume v 0
k k(T)
Cp Cp ( T )
47
Energy Equation
Simplification
d
dT
k kt
0
dy
dy
Cp
t
k
t
Pr
t
q"W
Cp
Pr
LHS
kt
dT
qW"
dy
dy
dT
1
Pr Pr
t
RHS
~ 1 mm T ~ 1000oC
(P, T)
(T)
k k(T)
Cp Cp ( T )
Energy Equation
Two Solutions: Motivation Tnear-wall ~ 1000oC
Properties
LHS
Tf
qw"
TW
dT
f c p w u Tw T f
qw"
Tf
LHS
TW
Assume
"
w
dT
P P P
0 P ~ constant
x y z
c pw u T f
qw"
log
Tw
T
T
f
Gases Only Pr ~ 1
49
Energy Equation
Solution
y
RHS
y 0
dy
1
Pr Pr
t
Viscous Region
Pr < 5
Turbulent Region
Pr > 0.5
RHS
T Pr y
T
Prt u P
y
T
y
T
Pr < 5
y - intersection
T
Pr > 0.5
50
T A Ln y B
y
T
y
T
y - intersection
T
- Variable Properties
c p u TW T
Standard
qW"
u T
qW"
log
TW
Modified
51
Effects Considered
Variables
Constant
Launder et al (1973)
Diffusion
Angelberge r et al (1997)
Diffusion
cp, k
Han et al (1997)
, cp, k
, , cp, k
Nijeweme et al (2001)
, cp, k
Park et al (2009)
Diffusion
cp, k
, cp, k
(Mo/ring only)
52
T+ Profile
T Pr y
Launder et al (1973)
T
Rakopoulos et al (1997)
Prt u P
y yT
T Pr
Angelberge r et al (1997)
Han et al (1997)
y yT
2.075 Log e
y 13.2
3.9
y 13.2
y 40
See Below
y 40
c p u TW T
q"W
cp u T
q"W
cp u T
q"W
cp u T
q
"
W
T
Log e W
T
T
Log e W
T
T
Log e W
T
y 40
1
1
1
Loge 40
10.2384 P
Loge y
117.31
C
C Pr
C Pr
C 1Pr
53
c p u TW T
qW"
Pr y
Location: HT-1
Local +
Flame Arrival
~ 707 CA
60
30
Y+ = 13.2
0
650
690
730
770
810
Crank Angle
Engine Operating Point 1
Courtesy CD-Adapco
55
Ranganathan, R. and Viskanta, R. "Natural Convection in a square cavity due to combined driving forces,"
Numerical Heat Transfer, vol. 14, pp. 35-59, 1988.
56
Results
20 x 20
40 x 40
80 x 80
Benchmark
Nuav
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
8.402
9.502
13.404
14.215
0.082
0.124
1.600
1.749
0.991
1.000
0.112
0.094
0.880
0.862
0.267
0.232
0.040
0.044
9.025
9.270
17.867
17.947
0.053
0.068
1.118
1.015
0.993
1.000
0.085
0.080
0.861
0.854
0.272
0.245
0.040
0.042
8.959
8.928
18.259
18.076
0.039
0.046
1.012
1.000
1.000
1.000
0.079
0.078
0.852
0.851
0.268
0.257
0.036
0.039
8.817
17.925
0.038
0.989
1.000
0.076
0.850
0.260
0.038
Numax
max
Numin
min
Umax
max
Vmax
Ranganathan, R. and Viskanta, R. "Natural Convection in a square cavity due to combined driving forces,"
Numerical Heat Transfer, vol. 14, pp. 35-59, 1988.
57
Large body of empirical correlations in the literature for Nusselt number in terms of
other dimensionless groups (Reynolds, Prandtl numbers) and a reference temperature
See example below
Nux h x / k
Pr
Rex U x /
h heat transfer coefficient
x distance from leading edge of plate
k thermal conductivity of the fluid
U characteristic velocity
density of the fluid
dynamic viscosity of the fluid
hx x
Nu X
0.0296 Re 4X/ 5 Pr1 / 3
k
Turbulent flow over a flat plate
1. Incropera, F. P. and Dewitt, D. P., Fundamentals of Heat and Mass Transfer, John Wiley, 2002.
2. Fox, R. W., McDonald, A. T. and Pritchard, P. J., Introduction to Fluid Mechanics, 6th edition, John Wiley, 2004.
58
In the post-CFD era, a 3rd approach to computing the heat transfer coefficients has
become available, namely, numerically.
Loosely coupled conjugate heat transfer (CHT) using CFD and FEA
59
qw" , L
f ,G Tw,G
(1)
qw" , L
f ,G Tw, L
(2)
qw" , L
f , L Tw, L
(3)
Equation (3)
Solid
Fluid
60
T Pr y (4)
T
A Ln y
(5)
y
T
y
T
y - intersection
T
u T
"
W
log
TW
(7 )
61
cP u *
T
(8)
u T
log
f , L Tw, L
TW
(9)
62
63
qw h f (T f Tw )
qw , Tw are unambiguous
LOCAL Quantities
Pointers
64
Mechanism
Fluid
HTC (W/m2-K)
Natural
Convection
Gases
2 50
Liquids
50 4000
Forced
Convection
Gases
10 500
Liquids
100 75,000
Boiling
300 1,000,000
Evaporation
300 50,000
Condensation
300 100,000
Phase Change
65
q"
4
S
4
sur
hr A TS Tsur
2
hr TS Tsur TS2 Tsur
66
In-Cylinder CFD
Iteration 1
HTC, Tgas
Assumed Twall
In-Cylinder CFD
Iteration 2
In-Cylinder CFD
Iteration 3
HTC, Tgas
HTC, Tgas
Empiricism
Problem formulation
Material properties
Wall treatment
Grid independence
Grid quality
Caution: Errors canceling out fortuitously
Natural Convection
Turbulent Flow in a 2D Cavity
Temperature
Velocity
Geometry
Reference data: Experiments
Cold Nu
Courtesy CD-Adapco
Hot Nu
k-epsilon with
low-Re mesh
69
Natural Convection
Turbulent Flow in a 2D Cavity
Velocity
Temperature
Two-layer model
Geometry
A=5
Courtesy CD-Adapco
70
71
Equally Important
(a) Local gas temp,
(b) HT model,
(c) Numerical resolution
Angelberger, C., Poinsot, T. and Delhay, B., Improving Near-Wall Combustion and Wall Heat Transfer
Modeling in SI Engine Computations, SAE Technical Paper Series, No. 972881, pp. 113-130, 1997.
72
Combustion Validation
Cylinder Pressures
Simulations: Angelberger et al (1997)
Measurements: Alkidas (1980)
CFD Simulations
Measurements
PCP = 25 bars
Ignition Timing
(-27 BTDC)
Crank Angle
1. Angelberger, C., Poinsot, T. and Delhay, B., Improving Near-Wall Combustion and Wall Heat Transfer
Modeling in SI Engine Computations, SAE Technical Paper Series, No. 972881, pp. 113-130, 1997.
73
DI Diesel Engine
Variation of
properties can have
a 4-fold Effect
Difficulty of
predicting flame
arrival
Investigator: Kleeman et al (2001)
1. Kleeman, A. P., Gosman, A. D. And Binder, K. B., Heat Transfer in Diesel
Engines: A CFD Evaluation Study, The Fifth International Symposium on
Diagnostics and Modeling of Combustion in Internal Combustion Engines
(COMODIA), July 1-4, Nagoya, Japan, 2001.
74
SI Engine
Variation of
properties can
have a 2-fold
effect
Firing Engine
1. Han, Z. and Reitz, R. D., A Temperature Wall Function Formulation for Variable-Density
Turbulent Flows with Application to Engine Convective Heat Transfer Modeling,
International Journal of Heat and Mass Transfer, Vol. 40, No 3., pp. 613-625, 1997.
Motoring Engine
Investigator: Han et al (1997)
HT Model: Han et al (1997)
Combustion Model: Abraham et al (1987)
Measurements: Alkidas (1980)
75
Cylinder Head
Coolant
Valves/Seats/Stem/Guide
Ports
Piston
Piston Rings Cylinder Liner
Cylinder Liner
Piston underside / Lube oil jets / Crankcase oil splash
Friction between piston and liner
Block
Coolant
77
Cylinder Liner
Integral with the block and is in contact with the cylinder gases
Thermal distortion of the liner and piston can impact piston component
of engine friction.
Engine Block
High mass, high cost component in the vehicle. Therefore, thermal
optimization using a model is necessary
78
Exhaust Valves
The relatively high temperatures of the exhaust valves can cause knock
Exhaust Port
Complex thermal physics in the exhaust port needs to be modeled to
ensure accuracy of modeling downstream exhaust components.
79
Intake Manifold
Important to optimize for mixing of EGR gases with intake air.
Important to optimize for cylinder variability.
80
Valve bridge
1. Finlay et al, Factors influencing combustion chamber wall temperatures in a liquid
cooled, automotive, spark ignition engine, Proceedings Institution of Mechanical
Engineers, vol. 199, no. D3, pp. 207-214, 1985.
81
82
Measurement locations
on the liner
Sugihara, T., Shimano, K., Enomoto, Y., Suzuki, Y., Emi, M., Direct heat loss to combustion
chamber walls in a DI Diesel Engine, SAE Technical Paper 2007-24-006, 2007.
83
MW/m2
Measurements
MW/m2
84
85
Li, C-H, Piston thermal deformation and friction considerations, SAE Paper 820086, 1982
86
Furuhama., S, et al Temperature distribution of piston rings and piston in high speed diesel
engine, Bull. JSME, vol. 22, no. 174, pp. 1788-1795, 1979
87
Exhaust Valves
Measured Temperatures
88
Exhaust Manifold
Predicted Temperatures On Inside Surface Using CFD
89
Bay-to-Bay Breathing
Schematic
1. Ranganathan, R., "Crankcase pumping network flow model for a four stroke engine," 1999 SAE Congress, Cobo
Center, Detroit, March 1-4, 1999, SAE paper No. 1999-01-0215, SAE Special Publication SP-1451.
90
Bay-to-Bay Breathing
Interactions
1. Ranganathan, R., "Crankcase pumping network flow model for a four stroke engine," 1999 SAE Congress, Cobo
Center, Detroit, March 1-4, 1999, SAE paper No. 1999-01-0215, SAE Special Publication SP-1451.
91
Bay-to-Bay Breathing
Results
1. Ranganathan, R., "Crankcase pumping network flow model for a four stroke engine," 1999 SAE Congress, Cobo
Center, Detroit, March 1-4, 1999, SAE paper No. 1999-01-0215, SAE Special Publication SP-1451.
92
Bay-to-Bay Breathing
Results
1. Ranganathan, R., "Crankcase pumping network flow model for a four stroke engine," 1999 SAE Congress, Cobo
Center, Detroit, March 1-4, 1999, SAE paper No. 1999-01-0215, SAE Special Publication SP-1451.
93
Bay-to-Bay Breathing
Results
1. Ranganathan, R., "Crankcase pumping network flow model for a four stroke engine," 1999 SAE Congress, Cobo
Center, Detroit, March 1-4, 1999, SAE paper No. 1999-01-0215, SAE Special Publication SP-1451.
94
Bay-to-Bay Breathing
Results
1. Ranganathan, R., "Crankcase pumping network flow model for a four stroke engine," 1999 SAE Congress, Cobo
Center, Detroit, March 1-4, 1999, SAE paper No. 1999-01-0215, SAE Special Publication SP-1451.
95
96
97
Patrick Lee and Michael Wahl, Cylinder Cooling for Improved Durability on an Opposed-Piston Engine,
SAE 2012-01-1215, 2012
98
AXIAL
Patrick Lee and Michael Wahl, Cylinder Cooling for Improved Durability on an Opposed-Piston Engine,
SAE 2012-01-1215, 2012
99
Temperature Variation
In-Cylinder Walls Design 1
AXIAL
CIRCUMFERENTIAL
Patrick Lee and Michael Wahl, Cylinder Cooling for Improved Durability on an Opposed-Piston Engine,
SAE 2012-01-1215, 2012
100
Temperature Variation
In-Cylinder Walls Design 2
AXIAL
CIRCUMFERENTIAL
Patrick Lee and Michael Wahl, Cylinder Cooling for Improved Durability on an Opposed-Piston Engine,
SAE 2012-01-1215, 2012
101
Temperature Variation
In-Cylinder Walls Design 3
AXIAL
CIRCUMFERENTIAL
Patrick Lee and Michael Wahl, Cylinder Cooling for Improved Durability on an Opposed-Piston Engine,
SAE 2012-01-1215, 2012
102
Temperature Variation
In-Cylinder Walls Design 4
AXIAL
CIRCUMFERENTIAL
Patrick Lee and Michael Wahl, Cylinder Cooling for Improved Durability on an Opposed-Piston Engine,
SAE 2012-01-1215, 2012
103
Physics of Boiling
Nucleate and Film Boiling
Sudden Transition
nucleate boiling film boiling
film boiling nucleate boiling
104
Rohsenow, 1952
105
Inlet:
v=0.25 m/s , 1.00 m/s
p=1 bar, 2 bar, 3 bar
T=90 C
Liquid
50% water + 50% ethylene glycol by volume
Heating wall
constant temperature
All other walls
adiabatic
Courtesy CD-adapco
106
Courtesy CD-adapco
107
Experiment
Pressure = 1 bar
STAR-CCM+ HBM
Experiment
Pressure = 2 bar
STAR-CD
E2P
STAR-CD
E2P
Courtesy CD-adapco
STAR-CCM+ HBM
108
Mesh statistics:
150k Fluid cells with 2 layer extrusion cells
450k Structural cells
Boundary Conditions assigned realistic values
but without detailed spatial variation
Courtesy CD-adapco
109
Fluid
Courtesy CD-adapco
110
Courtesy CD-adapco
111
Courtesy CD-adapco
112
Pressure = 1 bar
Flow rate = 100%
113
Pressure = 3 bar
Flow rate = 100%
114
115
116
1 bar
2 bar
Reduced boiling
3 bar
80 % flow
Courtesy CD-adapco
100 % flow
120 % flow
117
Courtesy CD-adapco
118
119
120
Model Development
121
122
123
124
125
126
127
CHEN Model
AVL Model
Measurements
128
Rationale
Raj Ranganathan and Edward Cryer, III, Cooling Pump Cavitation Suppressor, Patent No: US 6932029 B2,
August 23, 2005.
129
Cavitation Suppressor
Locomotive Cooling System
Coolant Level
Coolant
Tank
Computational domain
Axis
Not to Scale
35 mm
X
few inches
K
Pressure inlet BC
Grounding
the pressure
Raj Ranganathan and Edward Cryer, III, Cooling Pump Cavitation Suppressor, Patent No: US 6932029 B2,
August 23, 2005.
130
Temperature (K)
Dynamic Viscosity
(N-s/m2)
Prandtl
Number
273
4.0
50,000
300
0.5
6,250
325
0.1
1,250
350
0.04
500
375
0.016
200
400
0.01
125
425
0.006
75
Andy Sutherland, Fuel economy and cabin heating improvements thanks to thermal management
solutions installed in a diesel hybrid electric vehicle, SAE 2010-01-0800; Courtesy of Ricardo
131
Shayler, P. J., Baylis, W. S. and Murphy, M., Main Bearing Friction and Thermal Interaction During the Early Seconds of
Cold Engine Operation, Journal of Engineering for Gas Turbines and Power, January 2005, Vol. 127, pp. 197-205.
132
Friction Losses
SI and CI Engines
1. Ball, W. F., Jackson, N. S., Pilley, A. D. and Porter, B. C., The friction of a 1.6 liter automotive engine
gasoline and diesel, SAE paper 860418, 1986
133
Zammit, Jean-Paul, Shayler, P. J., Gardiner, R., and Pegg, I., Investigating the Potential to Reduce Crankshaft Main
Bearing Friction During Engine Warm-up by Raising Oil Feed Temperature, SAE 2012-01-1216, 2012.
134
Zammit, Jean-Paul, Shayler, P. J., Gardiner, R., and Pegg, I., Investigating the Potential to Reduce Crankshaft Main
Bearing Friction During Engine Warm-up by Raising Oil Feed Temperature, SAE 2012-01-1216, 2012.
135
a dP y
1
u
2 dx a
4
2
Continuity
Momentum
12 Q
dP
dx
a3
Y = a/2
Y=0
du
d T
2
dy
dy
2
Energy
BC
dT
0 at y a / 2
dy
T Tref at y 0
Solution
12 Q y 4
3
k a
a3 y
12 24 Tref
Prandtl
Number
(typical)
Fluid
Example
Mean
Velocity
Br x dT
Closed
Form: Local
Temp Rise
Mean Temp
Increase
Closed
Form dP
m/s
deg-C
deg-C
Pa
Gases
20
0.4
0.9
0.12
48
10
Water
20
0.8
480
100
Ethylene
glycol
20
40
90
4800
1000
Engine oil
20
400
900
80
48000
10000
Engine oil
20
4000
9000
800
480000
Gases
100
10
23
1.2
240
Gases
200
40
90
3.2
480
137
Steve Zoz, Steve Strepek, Marc Wiseman, Cheng Qian, Engine Lubrication System Model for Sump Oil
Temperature Prediction, SAE 2001-01-1073, 2001
138
Steve Zoz, Steve Strepek, Marc Wiseman, Cheng Qian, Engine Lubrication System Model for Sump Oil
Temperature Prediction, SAE 2001-01-1073, 2001
139
Steve Zoz, Steve Strepek, Marc Wiseman, Cheng Qian, Engine Lubrication System Model for Sump Oil
Temperature Prediction, SAE 2001-01-1073, 2001
140
Steve Zoz, Steve Strepek, Marc Wiseman, Cheng Qian, Engine Lubrication System Model for Sump Oil
Temperature Prediction, SAE 2001-01-1073, 2001
141
Steve Zoz, Steve Strepek, Marc Wiseman, Cheng Qian, Engine Lubrication System Model for Sump Oil
Temperature Prediction, SAE 2001-01-1073, 2001
142
Component Temperatures
Turbocharged SI Engine
Bozza F., Fontana G, Galloni E and Torella E, 3D-1D Analysis of the Turbulent Flow Field, Burning
Speed and Knock Occurrence in a Turbocharged SI engine, SAE 07NAPLES-69, 2007.
143
Wall Temperatures
Turbocharged SI Engine
Bozza F., Fontana G, Galloni E and Torella E, 3D-1D Analysis of the Turbulent Flow Field, Burning
Speed and Knock Occurrence in a Turbocharged SI engine, SAE 07NAPLES-69, 2007.
144
David Luff, Theo Law, Paul Shayler and Ian Pegg, The effect of piston cooling jets on diesel engine
piston temperatures, emissions and fuel consumption, SAE 2012-01-1212
145
David Luff, Theo Law, Paul Shayler and Ian Pegg, The effect of piston cooling jets on diesel engine
piston temperatures, emissions and fuel consumption, SAE 2012-01-1212
146
David Luff, Theo Law, Paul Shayler and Ian Pegg, The effect of piston cooling jets on diesel engine
piston temperatures, emissions and fuel consumption, SAE 2012-01-1212
147
David Luff, Theo Law, Paul Shayler and Ian Pegg, The effect of piston cooling jets on diesel engine
piston temperatures, emissions and fuel consumption, SAE 2012-01-1212
148
David Luff, Theo Law, Paul Shayler and Ian Pegg, The effect of piston cooling jets on diesel engine
piston temperatures, emissions and fuel consumption, SAE 2012-01-1212
149
Jets Closed
Piston temperatures higher by 20-80oC
CO lower by 5-10%
NOx higher by 3%
Reduces engine oil flow through the lube circuit
Greater flow through internal (pump) bypass
Higher pump out pressure
Higher pump power consumption (parasitic loss)
Compensated by better combustion due to higher
piston temperatures
Active Control of Jets
CO lower by 6%
NOx higher by 1%
With NO fuel economy change
David Luff, Theo Law, Paul Shayler and Ian Pegg, The effect of piston cooling jets on diesel engine
piston temperatures, emissions and fuel consumption, SAE 2012-01-1212
150
Oil Circuit
sump
Conduction
through engine
structure
Coolant Circuit
Cabin
heater
radiator
Cabin
Evaporator
air intake
AC Circuit
condenser
Ambient
Andy Sutherland, Fuel economy and cabin heating improvements thanks to thermal management
solutions installed in a diesel hybrid electric vehicle, SAE 2010-01-0800; Courtesy of Ricardo
151
Andy Sutherland, Fuel economy and cabin heating improvements thanks to thermal management
solutions installed in a diesel hybrid electric vehicle, SAE 2010-01-0800; Courtesy of Ricardo
152
Concept
Hot coolant flask
Andy Sutherland, Fuel economy and cabin heating improvements thanks to thermal management
solutions installed in a diesel hybrid electric vehicle, SAE 2010-01-0800; Courtesy of Ricardo
153
10%
NEDC
Artemis Urban
Artemis Road
8%
6%
4%
2%
0%
Coolant
thermal flask
(2L)
Coolant heat
battery (4L)
Split sump
(40% active
volume)
Split sump
(20% active
volume)
Clutched
water pump
Electrical
water pump
Andy Sutherland, Fuel economy and cabin heating improvements thanks to thermal management
solutions installed in a diesel hybrid electric vehicle, SAE 2010-01-0800; Courtesy of Ricardo
Intelligent
thermostat
Oil heat
battery (1L)
154
Source: Toyota
Thermal model:
Flask was modelled by controlling two ball valves to
connect the flask circuit with the main
Flask dumps into the main cooling system a 2 litre
volume of 80C coolant modelled by addition of
flow sources
Source: Toyota
Andy Sutherland, Fuel economy and cabin heating improvements thanks to thermal management
solutions installed in a diesel hybrid electric vehicle, SAE 2010-01-0800; Courtesy of Ricardo
155
Source: Schatz
156
Return
Basket
Pick-up
Sump
Thermal Model
The oil sump basket was modelled by reducing the oil amount
respectively to:
40% of the original volume (from 4.5 litres to 1.8 litres )
20% of the original volume (from 4.5 litres to 0.9 litres )
Andy Sutherland, Fuel economy and cabin heating improvements thanks to thermal management
solutions installed in a diesel hybrid electric vehicle, SAE 2010-01-0800; Courtesy of Ricardo
157
Andy Sutherland, Fuel economy and cabin heating improvements thanks to thermal management
solutions installed in a diesel hybrid electric vehicle, SAE 2010-01-0800; Courtesy of Ricardo
158
12
11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Oil pump
Oil pipe to Filter
Oil Filter
Heater Matrix
Oil pick-up pipe
Wet sump
Outlet by-pass pipe
Outlet throttle
Central exhaust stream throttle
Exhaust pipe
Catalytic Converter
Exhaust Manifold
Inlet Throttle
Inlet by-pass pipe
ENGINE
10
13
1
14
9
3
BATTERY
CONTROL UNIT
Oil Temp
Input
Courtesy of Ricardo
159
160
161
162
Engine Compartment
163
Exhaust Manifold
Turbine Housing
Wire Harness
Catalytic Converter
Compressor
Catalytic Converter
Floor Pan
164
Exhaust Manifold
650
650
800
Radiator Exit
100
Brake Booster
75
400-600
800
300-600
Battery
75
Engine Mount
90
Transmission Oil
140
Engine Oil
140
80-85
165
Hose Temperatures, oC
25 mm gap
25 mm gap,
2 m/s air
100 mm gap
Source Temperatures, oC
166
40 mm gap, no shield
40 mm gap, with shield
40 mm gap, no shield, 2m/s air
100 mm gap, no shield
Source Temperatures, oC
167
Engine Compartment
Heat Transfer Modelling Considerations
Goals of CFD
Prevent thermal problems
Guide material selection
Locate thermocouples for confirmation
Local HTC and Tf for transient component radiation models
Pointers
Couple exhaust gas flow with the engine compartment model
Heat transfer due to convection, conduction and radiation.
Uncertainties in emissivity (surface degradation, dirt, moisture)
Lateral conduction in component walls must be included.
Difficulties of modeling natural convection during soak.
Role of component radiation models.
168
Engine Compartment
Thermal Radiation Shields
169
Freedom to make
design changes
Cost of making
design changes
Knowledge of product
Predict Transient Cylinder Temperatures & Exhaust Flow Rates using Engine Cycle Simulation
Time averaging the Thermocouple model results yields an equilibrium thermocouple temperature
Equation 5
1. Caton, J.A., Comparisons of Thermocouple, Time-Averaged and Mass-Averaged Exhaust Gas Temperatures in a Spark Ignited
Engine, SAE Technical Paper 820050, 1982
2. Caton, J.A. and Heywood, J.B., An Experimental and Analytical Study of Heat Transfer in an .Engine Exhaust Port, International
Journal of Heat and Mass Transfer, Vol. 24, No. 4, pp. 581-596, April 1981.
3. Caton, J. A., Heat Transfer, Mixing and Hydrocarbon Oxidation in an Engine Exhaust Port, M.I..T., Ph.D. Thesis, February 1980.
171
Engine cycle simulation program used to predict transient (crank angle) exhaust gas temperatures
Thermocouple model Balance between energy storage, convection heat gain, radiation heat loss
Dependence of exhaust as temperatures to Load, Speed, Equivalence Ratio, Spark Timing examined
Mass-Averaged Exhaust Gas Temperatures represent the energy content of the gases
Time-Averaged Exhaust Gas Temperatures do not representative of the energy content of the gases
The Time-Averaged Exhaust Gas Temperatures were about 20oK higher than Thermocouple
Equilibrium Temperatures (both measured and modeled). This is due to the balance between
convection heat gain and radiation heat loss from the thermocouple
The Time-Averaged Exhaust Gas Temperatures were about 10% less than the Mass-Averaged Exhaust
Gas Temperatures
1. Caton, J.A., Comparisons of Thermocouple, Time-Averaged and Mass-Averaged Exhaust Gas Temperatures in a Spark Ignited
Engine, SAE Technical Paper 820050, 1982
2. Caton, J.A. and Heywood, J.B., An Experimental and Analytical Study of Heat Transfer in an .Engine Exhaust Port, International
Journal of Heat and Mass Transfer, Vol. 24, No. 4, pp. 581-596, April 1981.
3. Caton, J. A., Heat Transfer, Mixing and Hydrocarbon Oxidation in an Engine Exhaust Port, M.I..T., Ph.D. Thesis, February 1980.
172
2.24 g/s
Temperature
2.24 g/s
Temperature
469oK
137oK
173
8.67 g/s
2.89 g/s
Manifold Exit
174
947oK
876oK
Manifold Exit
175
947oK
876oK
Manifold Exit
2.89 g/s
8.67 g/s
Manifold Exit
Time Averaged Values
176
17.36 g/s
2.89 g/s
Manifold Exit
177
975oK
877oK
Manifold Exit
877oK
Manifold Exit
Manifold Exit
Time Averaged Values
179
Temperature Shortfall, oC
180
Thermocouple = 723oC
MAGT = 737oC
Thermocouple Emissivity = 1.0
181
Thermocouple = 723oC
MAGT = 737oC
Wall Temperature = 400oC
182
MAGT, oC
Radiation Error ~ 9oC 50oC
Courtesy of Showatech, Inc.
183
Time delay due to different ports being at different distances from manifold exit
For an Adiabatic Manifold, Mass Averaged Gas Temperature at Exit = Mass Averaged Gas
Temperature at Inlet
Example
184
185
Ranganathan, R., Turner, D. and Franchett, M., Exhaust Manifold Gas Temperature Predictions using
System Level Data Driven Modeling, SAE 2005-01-0698, 2005.
186
Ranganathan, R., Turner, D. and Franchett, M., Exhaust Manifold Gas Temperature Predictions using
System Level Data Driven Modeling, SAE 2005-01-0698, 2005.
187
188
189
HT Notes:
Compressor impacted by HT
(Bohn et al 2003)
Nick Baines, Karl Wygant and Antonis Dris, The analysis of heat transfer in
automotive turbochargers, Proc ASME Turbo EXPO 2009: Power for land, sea
and air, June 8-12, Orlando, Florida, ASME GT2009-59353
190
Bohn Dieter, Heuer Tom and Kusterer Karsten, Conjugate flow and heat transfer
investigation of a turbo charger: Part 1: Numerical Results, Proc ASME Turbo
Expo 2003, June 16-19, 2003 Atlanta, Georgia.
191
Bohn Dieter, Heuer Tom and Kusterer Karsten, Conjugate flow and heat transfer
investigation of a turbo charger: Part 1: Numerical Results, Proc ASME Turbo
Expo 2003, June 16-19, 2003 Atlanta, Georgia.
192
Exhaust After-Treatment
Definition of Problems
Rationale
Diesel engine after treatment devices remove NOx and particles from exhaust gas
Inject liquid HC for oxidation in DOC to enable DPF (Diesel Particulate Filter) regeneration
Inject liquid DEF (Diesel Exhaust Fluid) for NOx conversion in SCR (Selective Catalytic Reduction)
Spray dynamics
Mixing of vapors and exhaust gas currently inadequate
Objective: Improve evaporation and mixing
EGR (Exhaust Gas Recirculation)
High stresses due to hot spots
193
Exhaust After-Treatment
NOx Formation and Local Gas Temperatures
Seiji Yamamoto et al, Numerical simulation of diesel combustion with high EGR rate, 7 th
International Conference on Modeling and Diagnostics for Advanced Engine Systems
COMODIA 2008, July 28-31, 2008, Sapporo, Japan
194
Exhaust After-Treatment
Use of Mixers
Role of Mixers
Mixers improve the atomization and evaporation by changing the flow pattern of the injected
liquid and enhancing turbulence
Mixers speed up decomposition reactions (DEF) via same enhanced turbulence
Mixers improve the uniformity of the mixture thereby reducing potential of ammonia slip
(SCR), UHC (DOC) and efficient utilization of all devices.
Mixer
Mixer
195
Exhaust After-Treatment
Conventional Mixer Concepts
Yong Yi, Development of a 3D Numerical model for predicting spray, urea decomposition
and mixing in SCR Systems, SAE 07-FFL-26
196
Exhaust After-Treatment
Conventional Mixer Performance
Uniformity Index
1
1
2
X
X
V X dA
V dA
Yong Yi, Development of a 3D Numerical model for predicting spray, urea decomposition
and mixing in SCR Systems, SAE 07-FFL-26
197
1. Raj Ranganathan, Sandro Balestrino, Bob Straub and Sharon Li,Enhanced nozzle diffuser mixer for evaporation,
opened on 12 January 2009, filed with the US Patent Office on 10 November, 2009, USPTO Ser. No. 12/615618
2. Raj Ranganathan, Bob Straub, Sherif El Tahry,Nozzle diffuser mixer, opened on 13 May 2008, filed with the US
Patent Office on 13 July, 2008, USPTO Ser. No. 12/171865
198
Injector
Axis of pipe and cone
Cone
Diffuser
Exhaust pipe
Patent Pending
Nozzle
1. Raj Ranganathan, Sandro Balestrino, Bob Straub and Sharon Li,Enhanced nozzle diffuser mixer for evaporation,
opened on 12 January 2009, filed with the US Patent Office on 10 November, 2009, USPTO Ser. No. 12/615618
2. Raj Ranganathan, Bob Straub, Sherif El Tahry,Nozzle diffuser mixer, opened on 13 May 2008, filed with the US
Patent Office on 13 July, 2008, USPTO Ser. No. 12/171865
199
Injector
-- Residence Time
-- Mixing Length
-- Cone Surface Evaporation
Recirculation
Patent Pending
Axis
Exhaust pipe
1. Raj Ranganathan, Sandro Balestrino, Bob Straub and Sharon Li,Enhanced nozzle diffuser mixer for evaporation,
opened on 12 January 2009, filed with the US Patent Office on 10 November, 2009, USPTO Ser. No. 12/615618
2. Raj Ranganathan, Bob Straub, Sherif El Tahry,Nozzle diffuser mixer, opened on 13 May 2008, filed with the US
Patent Office on 13 July, 2008, USPTO Ser. No. 12/171865
200
Injector
Bigger Tumble Recirculation
Axis
Deflectors?
Exhaust pipe
Asymmetric Cone
1. Raj Ranganathan, Sandro Balestrino, Bob Straub and Sharon Li,Enhanced nozzle diffuser mixer for evaporation,
opened on 12 January 2009, filed with the US Patent Office on 10 November, 2009, USPTO Ser. No. 12/615618
2. Raj Ranganathan, Bob Straub, Sherif El Tahry,Nozzle diffuser mixer, opened on 13 May 2008, filed with the US
Patent Office on 13 July, 2008, USPTO Ser. No. 12/171865
201
1. Raj Ranganathan, Sandro Balestrino, Bob Straub and Sharon Li,Enhanced nozzle diffuser mixer for evaporation,
opened on 12 January 2009, filed with the US Patent Office on 10 November, 2009, USPTO Ser. No. 12/615618
2. Raj Ranganathan, Bob Straub, Sherif El Tahry,Nozzle diffuser mixer, opened on 13 May 2008, filed with the US
Patent Office on 13 July, 2008, USPTO Ser. No. 12/171865
202
203
204
After-Treatment Devices
CFD Process
Mesh Quality:
User Code:
Default
Constants
Droplet Break Up
ON
OFF
OFF
OFF
ON
ON
Wall Film
ON
ON
OFF
OFF
ON
ON
Droplet Collision
OFF
OFF
OFF
OFF
OFF
OFF
Particle Break-Up
Unsteady
Unsteady
Unsteady
Steady
Unsteady
Unsteady
5e-5
10
10
10000
10
10
5e-5
10
10
10000
10
10
5e-5
10
10
10000
10
10
1e-3
10
1
10000
10
5
1e-3
10
1
10000
10
5
1e-3
10
1
1250
10
3
~ 50
~ 50
~ 50
~ 32
~5
~1
~1
~1
~1
~1
~1
8.1
16.1
31.0
53.0
1.
2.
3.
4.
5.
6.
1.
2.
0.8
6.4
1.2 / 0
1.2 / 0
1.2 / 0
1.2 / 0
1.2 / 0
0.10 / 0.05
Solver Precision
Double
Double
Double
Single
Single
Single
Second
Second
Second
First
First
First
30-150
30-150
30-150
30-150
30-150
30-150
0.91
0.90
0.90
0.85
0.85
0.84
0.80
0.81
0.78
0.77
0.77
0.66
0.91
0.91
0.91
0.91
0.91
0.91
59.8
49.6
29.6
55.2
55.2
52.3
Y Range
208
3D porous media CFD model with solid & gas in local thermal equilibrium
Highly simplified chemistry: exhaust gas + HC -> exhaust gas
Evaporation of HC droplets
Energy and species source terms due to chemistry & evaporation
Constrained particle motion in the DOC & DPF through user code
Arrhenius expression: R = A TB e-C/T
Tuned constants with test data
A = 1.2e11, B = 0.0, C = 12218, T local gas temperature in oK
Chemistry in the DPF not accounted for
209
CFD
Test
Note:-Not to scale
3D porous media CFD model with solid & gas in local thermal equilibrium
Source terms in energy and species conservation equations modeled by
balancing convection mass transfer rate of the reacting species with
surface reaction rates using separate surface & gas concentrations
3 Reaction NOx conversion model: Fast, Standard & Slow SCR reactions
Species: NO, NO2, CO2, H2O, N2 and NH3
Two step de-coupled CFD:
1) Steady state using time averaged urea injection rate, spray models, full exhaust system
2) Steady state CFD model of SCR using BC (pressure, temperature, species) from above
211
Pressure Outlet
Convective Walls
212
NO2 SCR
Inlet
NH3 SCR
Inlet
NO SCR
Inlet
NH3 SCR
Outlet
NO SCR
Outlet
NO2 SCR
Outlet
Temperature
Tests
Velocity UI = 0.78
214
Since the time to light off is so critical in overall vehicle emissions, consideration
must be given at the design stage
Key components such as exhaust manifold and turbocharger can have a significant
effect on the light-off and emissions and so must be considered as early as
possible
This drives the requirement for an analysis toolset which can accurately predict
the effect of design changes, both detailed and concept, on the gas temperature
provided to the catalyst and ultimately the catalyst performance
Thermally induced stresses and fatigue life are other considerations
Courtesy of Ricardo
http://en.wikipedia.org/wiki/Catalytic_converter
215
Rationale
216
Hot Exhaust
Accelerator
Ambient Air
Annulus
Entrainer
Duct
Diffuser
Cooler Exit
Cooled Exhaust
PHENOMENA
ENTRAINMENT: Fluid flow is driven by pressure, body and viscous (shear)
forces. The net sum of these equals inertia forces. In this device, large radial
velocity gradients between high velocity exhaust gas and low velocity ambient
air create viscous forces that pull ambient air into the device. Pressure forces
play a smaller role.
MIXING: Enabled by radial velocity gradients and flow development.
VACUUM: The device (except the first nozzle) is below atmospheric pressure,
discouraging backflow through the annulus.
SIMPLEST-FORM: Small diameter pipe going into larger pipe!
DESCRIPTION
ACCELERATOR: Nozzle accelerates the gas to entrain sufficient ambient air into
the device. Noise absorber required if velocities are high.
ANNULUS: Air is drawn through the annulus between the accelerator and the
entrainer.
ENTRAINER: Entrained air mixes with the exhaust gas.
DUCT: Optimizing, mixing.
DIFFUSER: Lowers back pressure, rated power penalty and mixes the fluids.
SPACING: Spacing between accelerator exit and entrainer inlet increases
cooling.
CROSS-SECTION: Circular, oval or other form to meet requirements i.e.
manage trade offs between performance, penalties, limits etc.
COOLER-EXIT: May be slanted to change exit direction, back pressure.
Raj Ranganathan, B Deep, B Murthy, T Stewart, Fluid entrainment apparatus, Patent No.: US 7637099, Dec 29, 2009 .
217
Raj Ranganathan, B Deep, B Murthy, T Stewart, Fluid entrainment apparatus, Patent No.: US Dec 29, 2007637099, 9 .
218
Raj Ranganathan, B Deep, B Murthy, T Stewart, Fluid entrainment apparatus, Patent No.: US 7637099, Dec 29, 2009 .
219
Raj Ranganathan, B Deep, B Murthy, T Stewart, Fluid entrainment apparatus, Patent No.: US 7637099, Dec 29, 2009 .
220
Mud
Snow
Raj Ranganathan, B Deep, B Murthy, T Stewart, Fluid entrainment apparatus, Patent No.: US 7637099, Dec 29, 2009 .
221
Raj Ranganathan, B Deep, B Murthy, T Stewart, Fluid entrainment apparatus, Patent No.: US 7637099, Dec 29, 2009 .
222
Raj Ranganathan, B Deep, B Murthy, T Stewart, Fluid entrainment apparatus, Patent No.: US 7637099, Dec 29, 2009 .
223
Raj Ranganathan, B Deep, B Murthy, T Stewart, Fluid entrainment apparatus, Patent No.: US 7637099, Dec 29, 2009 .
224
Temperature
70
212 F
60
50
300 F
40
30
350 F
400 F
450 F
500 F
20
10
600 F
0.1
10
102
103
Time at Temperature, hr
104
105
225
Thermo-Mechanical Fatigue
Simulation Process for Exhaust Manifold, Turbine Housing
Design
Steady State CHT
Transient Solid Temperature
Stress Analysis
TMF Life Prediction
226
Thermo-Mechanical Fatigue
Geometry of Integrated Manifold
Heuer, T., Engels, B. and Wollscheid, P. , Thermomechanical analysis of a turbocharger based on conjugate
heat transfer, ASME Turbo Expo 2005, June 6-9, Reno-Tahoe, Nevada, US
227
Thermo-Mechanical Fatigue
Temperatures at Exterior and Interior Surfaces
Heuer, T., Engels, B. and Wollscheid, P. , Thermomechanical analysis of a turbocharger based on conjugate
heat transfer, ASME Turbo Expo 2005, June 6-9, Reno-Tahoe, Nevada, US
228
Thermo-Mechanical Fatigue
Temperature Distribution
Heuer, T., Engels, B. and Wollscheid, P. , Thermomechanical analysis of a turbocharger based on conjugate
heat transfer, ASME Turbo Expo 2005, June 6-9, Reno-Tahoe, Nevada, US
229
Thermo-Mechanical Fatigue
Temperature and Thermal Stresses in the Divider
Heuer, T., Engels, B. and Wollscheid, P. , Thermomechanical analysis of a turbocharger based on conjugate
heat transfer, ASME Turbo Expo 2005, June 6-9, Reno-Tahoe, Nevada, US
230
Thermo-Mechanical Fatigue
Thermal Stresses in the Volute / Manifold Area
Heuer, T., Engels, B. and Wollscheid, P. , Thermomechanical analysis of a turbocharger based on conjugate
heat transfer, ASME Turbo Expo 2005, June 6-9, Reno-Tahoe, Nevada, US
231
Heat Exchangers
Overview
Definition
232
Heat Exchangers
Performance Parameters
Parameters
233
Overview
Qi U Ai TH TC ,i
234
Overview
Qi U i Ai TH ,i TC ,i
235
Fundamentals of HVAC
Passenger Compartment Thermal Comfort
Objectives
Sub -Systems
Air conditioning
Heating
Ventilation
Math Model
Conservation of mass
Conservation of energy
Conservation of momentum (CFD)
Equation of state
Daltons law for mixtures
Psychrometrics relations
236
PV
6.23 kg
RT
Q m c p TF TI / t 1.54 kW
Equation of State
Conservation of energy
for a closed system
237
v A1
mA
RT
0.812 m3 / kg
PA1
VA
v A1
Equation of State
7.389 kg / min
238
Q ma h1 h2 1.84 kW
Conservation of energy
for a OPEN system
239
1.
2.
3.
4.
5.
6.
7.
8.
9.
241
11.
12.
13.
14.
15.
16.
17.
242
1.
2.
3.
4.
5.
6.
243
Krzysztof Cena, Jeremy Austin Clark, Bioengineering, Thermal Physiology and Comfort, Volume 10, Google Books
244
q Con AD
S ,O
1 dm
AD dt
TC ,O
RCL
Evaporation
Clothing
Surface Area
Energy Storage
American Society of Heating, Refrigerating and Air Conditioning Engineers, 2001 ASHRAE Handbook,
Fundamentals, SI Edition, pp. 8.1, Atlanta, 2001.
245
W/m2
Activity
Sleeping
40
Reclining
45
Seated, quiet
60
Driving vehicle
60-120
Resting/Sitting
Treadmill (2 mph)
Free Walking (2 mph)
Head
3.2
4.2
7.2
Chest
2.5
3.6
4.8
Back
2.4
3.2
4.7
Hands
4.6
7.2
11.6
Thighs
2.8
5.0
8.7
Legs
3.7
10.5
11.8
Mean
3.1
5.8
8.4
246
Subscripts
C, conv Convection heat flux from clothing outer surface of clothing
C, rad Radiation heat flux from outer surface of clothing
247
Energy added to the cabin (heating) by the HVAC system during cold weather
enthalpy lost by the HVAC air flow
Energy removed from the cabin (cooling) by the HVAC system during warm
weather enthalpy gained by the HVAC air flow
Infiltration (leakage) driven by pressure differences across cracks
Conduction heat transfer through walls doors, windows, windscreens, roof,
floor panel etc.
Direct and Indirect solar irradiation on cabin exterior surfaces
Long wave radiation exchange between cabin exterior and surroundings
De-icing and de-fogging of windshield
Convection Heat Transfer between cabin air and vehicle interior surfaces
Convection and evaporative Heat Transfer between cabin air and
occupants
Infiltration Enthalpy transport due to air mass transfer (leakage) into
cabin
Enthalpy change of air mass flow from the HVAC system
qLeakage
.
qBody q L,S q L, R q C ,S q C , R
Solar Radiation
Independent Parameters
The earths location with respect to the sun time of day, day of year
The earths rotation and tilt
The location on the earth latitude and longitude
The surface angle solar altitude, solar azimuth, surface tilt angle,
angle of incidence
Radiation properties of the surface next slides
251
Glazing
Visible
Solar
Conventional
80
76
16
IR reflective
73
52
37
11
IR absorptive
76
53
41
Sullivan, R., and Selkowitz, S., Effects of Glazing and Ventilation Options on Automobile Air
Conditioner Size and Performance, SAE Paper No. 900219, 1990
252
1
Transmittance
Reflectance
Absorptance
0
0
100
253
Air Management
Distribution of Air
Overview
254
Static Pressure
System
Blower
Efficiency
Power
Flow Rate
255
Refrigeration Cycle
First Law and Coefficient of Performance
QH
Expansion Device
Compressor
Condenser
QH QL = W
COP = QL / (QH QL)
Evaporator
QL
Low Temperature Heat Source CABIN Air, TL
Temperature, T
Reversible Processes
TH
Isentropic compression
Isothermal heat rejection
Isentropic expansion
Isothermal heat addition
TL
4
Entropy, s
257
COP
258
Van Wylen, G.J and Sonntag, R.E., Fundamentals of Classical Thermodynamics, John Wiley, 1985
Condenser Purpose:
0.9
COP \ COPCarnot
0.6
30
60
260
Evaporator Function:
0.9
COP \ COPCarnot
0.6
-20
261
Overview
262
Windshield Defrosting
Computational Fluid Dynamics Study
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of
Automobile Windshield with Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/201201-1219.
263
Windshield Defrosting
Parameters Investigated
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of
Automobile Windshield with Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/201201-1219.
264
Windshield Defrosting
Velocity Vectors
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of
Automobile Windshield with Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/201201-1219.
265
Windshield Defrosting
Velocity Vectors
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of
Automobile Windshield with Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/201201-1219.
266
Windshield Defrosting
Velocity Vectors
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of
Automobile Windshield with Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/201201-1219.
267
Windshield Defrosting
Velocity Vectors
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of Automobile Windshield with
Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/2012-01-1219.
268
Windshield Defrosting
Contours of Velocities
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of Automobile Windshield with
Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/2012-01-1219.
269
Windshield Defrosting
Contours of Turbulent Kinetic Energy
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of Automobile Windshield with
Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/2012-01-1219.
270
Windshield Defrosting
Contours of Local Nusselt Number
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of Automobile Windshield with
Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/2012-01-1219.
271
Windshield Defrosting
Average Nusselt Number for Different Designs
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of Automobile Windshield with
Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/2012-01-1219.
272
Windshield Defrosting
Average Nusselt Number Versus Reynolds Number
Ashok Kumar, M. and Kanniah, K., "Computational Investigation for Flow and Heat Transfer Characteristics of Automobile Windshield with
Impinging Slot Jets," SAE Technical Paper 2012-01-1219, 2012, doi:10.4271/2012-01-1219.
273
274
275
14. When a tetrahedral mesh is used, a layer of prism cells should be used, aligned
parallel to the solid surface.
15. A mass flow outlet boundary condition should not be used.
16. Default model parameters (such as under-relaxation, convergence criteria etc.)
should be used. There are sometimes subtleties underpinning these values and
may not readily apparent to the user.
276
23. The mesh should be refined in regions of high gradients, i.e. near leading and
trailing edges of blades etc.
24. When using wall functions, it is necessary to follow the guidelines provided by the
software supplier regarding the mesh size at the walls and therefore y+.
277
278
279
Other HT Problems
280
Thank You
281