Engine Cooling: " Latest Trends in Design & Development of I.C.Engines "

Engine Cooling
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
The Cooling System
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Contents
Functional requirements
Modern Techonologies
Failure modes
Analysis tools
Design validation tools
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Functional Requirements
From the perspective of thermodynamics the cooling

system is a Crucial system.
The cooling system is required to:

Control temperatures at critical locations for
Durability
Deposit control
Knock control
Control oil temperature
In some installations
Cool incoming charge after turbocharger
Cool exhaust gas for EGR
Provide passenger compartment heat
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Modern Techonologies
Quantify critical temperatures

Variation with application
Durability expectations
Duty-cycle
Measurable locations
Cooling system size

Frontal area
Maximum coolant temperature
Underhood temperatures
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Tracking the Fuel Energy - Naturally Aspirated
Pumping work
Piston work Useful work

transfers
Work used to
drive subsystems
Work used to
and accessories
Fuel Energy overcome friction
Heat transfer to oil

Heat rejection
In- Heat transfer through
Cylinder Heat transfer to
through radiator
Energy coolant
cylinder walls
Heat rejection
from surfaces
Heat transfer in
to ambient
exhaust port
Energy leaving Heat transfer in

cylinder through exhaust manifold
exhaust valve and remainder of
system
Energy leaving
through tailpipe
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Failure Modes
Thermal fatigue
Cylinder heads
Pistons
Head gaskets
Exhaust manifolds
Lubricant breakdown
Ring deposits
Valve sticking
Reduced oil drain interval
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Component Thermal Loading Issues
1. Cylinder Head
Cylinder head thermal fatigue
Severe temperature gradients
Potential for yielding in valve bridges
Controlling gradients is often as important as controlling
maximum temperature
Proving durability is extremely difficult
Aggressive thermal cycles may drive cracking, but design
changes to eliminate the cracks do not necessarily prove the
design
Careful, validated FE analysis, used in conjunction with
historical database, is recommended
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2. Cylinder Head Components

Valve seats
Loosening due to thermal cycles
Recession due to high temperature
Valves
Guttering and burning affected by high temperature
Head gaskets
Loss of seal due to deep thermal cycle
Exhaust manifolds
Cracking, loss of seal, bolt breakage due to thermal
cycles
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3. Piston and Rings
Thermal fatigue of piston crown
Gradients not as severe, but aluminum fatigue strength
drops rapidly with temperature
Thermal cycle testing, in conjunction with FE analysis to
validate durability
Ring sticking and deposits

Oil breakdown (oxidation) increases exponentially with
temperature
215 degrees C maximum at top ring
(some will allow higher in light duty-cycle applications)
Undercrown
Thermal loads contribute to pin boss cracking
Undercrown oil coking
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4. Cylinder Wall
Thermal loading contributes to cylinder bore

distortion
Impacts oil consumption, noise, piston scuffing
Controlling temperature variation around perimeter goal
of 15 C
Aggravated with siamesed cylinders
Piston thermal expansion must be carefully

quantified to ensure correct clearance over wide
operating range
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Cooling Circuit
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Cooling Circuit
a. Series Flow
Simple, efficient cooling

jackets
Minimal external
plumbing, especially in
front engine / rear drive
installations
Difficult to achieve
interbore cooling
Adequate balance can be
achieved with gasket
drillings
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Cooling Circuit Parallel Flow
b. Parallel Flow
Longer warm-up
Control over block and
head proportions
Minimal external plumbing
in transverse installations
Reduced pressure drop
Reduced coolant
temperature to head
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Cooling Circuit
c. Cross Flow
Low pressure header
Excellent cylinder
balance
Complex jackets limited Thermostat
to larger engines
Inlet and outlet can be at
either end of engine
Increased cost
Increased warm-up time
High pressure header

Supply from pump
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Meeting Cylinder Circumferential Temperature
Requirements
Primary flow direction

Ensuring balance
between cylinders
Ensuring flow between
cylinders
Ensuring backside flow
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Cylinder Jacket Considerations
Open versus Closed Deck
Temperature control at TRR
Cylinder distortion
Head gasket sealing
Cooling Jacket Length

Cylinder runs relatively cool
Primary heat rejection is from piston
Trend is toward shorter jackets
Increases heat rejection to oil
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Jacket Flow Optimization
Goals
Sufficient velocity in
critical regions
Velocities not too high
erosion, especially with
aluminum
Avoid stagnant regions
Coolant volume low for
rapid warm-up
Venting
Design Levers
Flow driven by
Pressure differential
Restriction
Velocity increased by
reducing flow area
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Cylinder Cooling Jacket Length
Trend toward shorter jackets

Overcooling near bottom ring reversal
Reduce oil viscosity for fuel efficiency
Mid-stop wet liner engines
Concerns
Increased heat rejection to oil
Reduced volumetric efficiency
Resulting piston and ring temperatures
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Water Pump and its Design
Water Pump Function:
To provide an appropriate coolant flow rate through the engine to
remove the excess energy of combustion for maintaining engine
temperature.
Water Pump Design Considerations:

Package well on or around the engine
Be inexpensive
Be reliable and durable
Be capable of being manufacture in large quantities
Be able to perform adequately at a variety of engine speeds and
loads
Be designed to reduce engine parasitic losses and thus maximize
fuel economy
Be tolerant to cavitation or cavitation free
Be capable of accommodating an appropriately sized pulley ratio
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Water Pump Design Flowchart
No. of vanes
Calculation of Required
water flow from Heat Outlet Vane Width
Balance Sheet
Check for
Diameter
Pump Head is decided Ratio
based on Bench-marked
data.
Outlet Vane Angle Outlet Vane Diameter
Pump Speed is finalized.
Peripheral Velocity at
Pump Specific Speed Outlet
Eye Diameter Inlet Vane Width Inlet Vane Angle
Overall Efficiency Impeller Inlet Diameter
Hydraulic Efficiency
Shaft Power HUB Diameter
Volumetric Efficiency
Mechanical Efficiency Pump shaft Torque Pump Shaft Diameter
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Algorithm for Water Pump Design
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Algorithm-CAD software Interface
Interface between Algorithm and CAD software
helps in Rapid Product Development
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23
Pump CAD Models
C/S of Single-Arc
Volute Volute Impeller Vane
Curve
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24
Component Temperature Control
Coolant required to control Wall temperature undergoes small
temperatures at critical points for swing on combustion chamber
durability and oil control. In spark- surface through engine operating
ignition engines knock margin is cycle.
also influenced. 15-20 oC cast iron
8-10 oC aluminum
450
350
250
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Circuit Modeling
GT-Cool circuit model and

computed pressures
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CFD as a Development Tool
Cooling System
CFD is used to evaluate:
Energy losses
Flow distributions and coolant velocity at critical locations (e.g.
injector, valve bridges, etc.)
Provide boundary conditions for structural analysis
Typical components:
Cylinder heads and blocks
Oil coolers, thermostat housings, water pumps, etc.
System level modeling done with 1-D code, e.g. FLOWMASTER
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Cylinder Blocks and Heads
Results
Flow distributions through system
Velocities at critical locations
Pressure drops
Heat transfer coefficients for
structural Analysis
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Water Pump
Spatial Distribution of Coolant Temperature Along Cutting Plane Y
Flow Separation
Zones
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Design Validation Tools
Flow visualization
Bench tests
Water pump mapping
Deaeration
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Flow Visualization
Full scale Plexiglas modeling

Water seeded with neutral buoyancy particles
High speed photography
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Water Pumps Testing
Water pump performance at

changing speeds
Rig Testing
Power input
Pressure Head
Inlet and outlet pressure
Efficiency
Cooling system
Air entrainment and characteristic
cavitation
Coolant Flow Rate
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Filling, Venting, and Deaeration
Vent line Stand pipe
Baffle
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Conclusions
Downsizing Trend of engines is putting heavy demand in
optimum design of cooling circuit which comprises of
- Correct estimation of water flow and pressure head

requirements
-Type of water pump such as forward / backward / Closed
vanes
-Design of volute for transforming most of kinetic energy
into pressure energy at the same time maintaining effective
water velocities for adequate heat transfers at walls
Simulation of Pressure, Velocity and Temperature Fields in

3D domain helps in optimising water jackets for less
pressure drops and for avoiding hot spots
Fore more accurate predictions consecutive Heat Transfer

Analysis is required
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Engine Cooling: " Latest Trends in Design & Development of I.C.Engines "

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Engine Cooling

From the perspective of thermodynamics the cooling

The cooling system is required to:

Quantify critical temperatures

Cooling system size

Piston work Useful work

Heat transfer to oil

Energy leaving Heat transfer in

2. Cylinder Head Components

Ring sticking and deposits

Thermal loading contributes to cylinder bore

Piston thermal expansion must be carefully

Simple, efficient cooling

High pressure header

Primary flow direction

Cooling Jacket Length

Trend toward shorter jackets

Water Pump Design Considerations:

Eye Diameter Inlet Vane Width Inlet Vane Angle

Overall Efficiency Impeller Inlet Diameter

Mechanical Efficiency Pump shaft Torque Pump Shaft Diameter

GT-Cool circuit model and

System level modeling done with 1-D code, e.g. FLOWMASTER

Full scale Plexiglas modeling

Water pump performance at

Vent line Stand pipe

- Correct estimation of water flow and pressure head

Simulation of Pressure, Velocity and Temperature Fields in

Fore more accurate predictions consecutive Heat Transfer

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