Validation and Optimization of Front End Cooling Module for Commercial Vehicle using CFD Simulation

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1 Validation and Optimization of Front End Cooling Module for Commercial Vehicle using CFD Simulation Ashok Patidar, Umashanker Gupta, Nitin Marathe VE Commercial Vehicles Ltd. INDIA (A VOLVO GROUP AND EICHER MOTORS JOINT VENTURE)

2 VE Commercial Vehicles Ltd - Overview Trucks : 5 Tons 40 Tons Haulage: 5 Tons 31 Tons Buses : 12 seater 65 seater School Buses: Tipper: 8 Tons 25 Tons Staff Buses: Articulated Tractor: 40 Tons City Buses & Special applications: Wednesday, September 26, Automotive Simulation World Congress 2

3 Contents Introduction Methodology Results Summery Wednesday, September 26, Automotive Simulation World Congress 3

4 Introduction In CFD modeling full vehicle is modeled considering front bumper, grille, cabin, cargo, surrounding under hood and under body components. The flow resistance of heat exchangers is considered using porous modeling technique. Heat exchanger performance data generated from 1-D Kuli software is taken in simulation using single pass Heat Exchanger model. Front End Cooling analysis is done for max power and max torque vehicle conditions. Wednesday, September 26, Automotive Simulation World Congress 4

5 Introduction Preliminary CFD Front End Cooling analysis is done on existing commercial vehicle and correlated well with field test results. Front grille Opening Intercooler Radiator Developed and validated CFD Front End Cooling process is implemented on new commercial Vehicle. Hot and cold air recirculation zones are identified in under hood compartment. Elimination of recirculation showed good improvement in radiator and intercooler cooling performance. Wednesday, September 26, Automotive Simulation World Congress 5

6 Methodology: CFD Simulation CAD Model CAD Cleanup Using HyperMesh Mesh Model Generation Using TGrid Setup and Solver (solve fundamental equations) Using Fluent Post Processing and Result Interpretation Using CFD Post Design Change Recommendation No Is met the targets? Yes Final Proto Test Verification Wednesday, September 26, Automotive Simulation World Congress 6

7 Methodology: Mesh Generation Non conformal mesh technique is used for heat exchanger modeling Tri Intercooler tank headers & Hoses Quad Intercooler Faces Non conformal Intercooler Wednesday, September 26, Automotive Simulation World Congress 7

8 Methodology: Mesh Generation Non conformal mesh technique is used for heat exchanger modeling Tri radiator tank headers & Hoses Quad radiator Faces Non conformal Radiator Wednesday, September 26, Automotive Simulation World Congress 8

9 Methodology: Mesh Generation Non conformal mesh technique is used for heat exchanger modeling Radiator Tank Radiator Radiator Fan Intercooler Under-hood components Volume Computational Domain Wednesday, September 26, Automotive Simulation World Congress 9

10 Methodology: Input Conditions Vehicle Speed & Fan Speed: Power Torque Vehicle Speed (KMPH) V1 V2 Radiator Fan Speed (RPM) N1 N2 Input Parameters for thermal analysis : Power Torque Radiator Coolant Flow Rate (kg/s) mc1 mc2 Coolant Inlet Temp ( C) Tcin1 Tcin2 Intercooler Charged air Flow Rate (kg/s) ma1 ma2 Charged air inlet temp ( C) Tain1 Tain2 Heat Exchanger Model: Ungrouped Macro Based Model is used Fix inlet temperature Note : Owing to IPR policy the numerical values cloud not disclosed Wednesday, September 26, Automotive Simulation World Congress 10

11 Methodology: Input Conditions Heat exchanger performance data generated through 1-D KULI software for computing heat rejection and outlet temperature of coolant and charged air : Radiator performance data : Coolant flow rate (kg/s) c1 c2 c3 c4 c5 c6 Air Flow rate (kg/s) Heat Transfer (W) a1 h11 h21 h31 h41 h51 h61 a2 h12 h22 h32 h42 h52 h62 a3 h13 h23 h33 h43 h53 h63 a4 h14 h24 h34 h44 h54 h64 a5 h15 h25 h35 h45 h55 h65 a6 h16 h26 h36 h46 h56 h66 Intercooler performance data : charged air flow rate (kg/s) c1 c2 c3 c4 c5 c6 Air Flow rate (kg/s) Heat Transfer (W) a1 h11 h21 h31 h41 h51 h61 a2 h12 h22 h32 h42 h52 h62 a3 h13 h23 h33 h43 h53 h63 a4 h14 h24 h34 h44 h54 h64 a5 h15 h25 h35 h45 h55 h65 a6 h16 h26 h36 h46 h56 h66 Note : Owing to IPR policy the numerical values cloud not disclosed Wednesday, September 26, Automotive Simulation World Congress 11

12 Results: Existing Vehicle Power Condition Intercooler Radiator Velocity = 5.2 m/s Velocity = 7.2 m/s Charged Air Flow direction Coolant flow direction Test Charged Air T =63.7 C CFD T = 76.5 C Test Coolant T = 4.7 C CFD T = 5.5 C Wednesday, September 26, Automotive Simulation World Congress 12

13 Results: Existing Vehicle Power Condition Intercooler Radiator Velocity = 5.2 m/s Velocity = 7.2 m/s Charged Air Flow direction Coolant flow direction Test Charged Air T =63.7 C CFD T = 76.5 C Test Coolant T = 4.7 C CFD T = 5.5 C Wednesday, September 26, Automotive Simulation World Congress 13

14 Correlation: Existing Vehicle Power Condition Predicted vehicle level performance of intercooler and radiator at fixed inlet temp Coolant/ Charged air side Ambient Temp = 28.5 C Test Intercooler CFD Correlation (%) Test CFD Inputs Radiator CFD Correlation (%) Flow Rate (kg/s) ma1 ma1 -- mc1 mc1 -- Inlet Temp ( C) Tain1 Tain1 -- Tcin1 Tcin1 -- CFD Outcomes Outlet Temp ( C) Taout1 Test Taout1 CFD -- Tcout1 Test Tcout1 CFD -- Temp Drop ( C) Heat Rejection (kw) Wednesday, September 26, Automotive Simulation World Congress 14

15 Results: Existing Vehicle Torque Condition Intercooler Radiator Velocity = 2.2 m/s Velocity = 3.1 m/s Charged Air Flow direction Coolant flow direction Test Charged Air T =47.3 C CFD T = 52.5 C Test Coolant T = 5 C CFD T = 5.8 C Wednesday, September 26, Automotive Simulation World Congress 15

16 Results: Existing Vehicle Torque Condition Intercooler Radiator Velocity = 2.2 m/s Velocity = 3.1 m/s Charged Air Flow direction Coolant flow direction Test Charged Air T =47.3 C CFD T = 52.5 C Test Coolant T = 5 C CFD T = 5.8 C Wednesday, September 26, Automotive Simulation World Congress 16

17 Correlation: Existing Vehicle Torque Condition Predicted vehicle level performance of intercooler and radiator at fixed inlet temp Coolant/ Charged air side Ambient Temp = 29 C Test Intercooler CFD Correlation (%) Test CFD Inputs Radiator CFD Correlation (%) Flow Rate (kg/s) ma2 ma2 -- mc2 mc2 -- Inlet Temp ( C) Tain2 Tain2 -- Tcin2 Tcin2 -- CFD Outcomes Outlet Temp ( C) Taout2 Test Taout2 CFD -- Tcout2 Test Tcout2 CFD -- Temp Drop ( C) Heat Rejection (kw) Wednesday, September 26, Automotive Simulation World Congress 17

18 New Vehicle Geometry Details Intercooler Radiator -Fan Module (IRFM) Wednesday, September 26, Automotive Simulation World Congress 18

19 Results: New Vehicle Under-hood Thermal Flow Field Hot air recirculation in front of intercooler Hot air recirculation in front of intercooler Path Lines coloured by Temperature ( C) Wednesday, September 26, Automotive Simulation World Congress 19

20 Results: New Vehicle Under-hood Thermal Flow Field Hot air recirculation in front of intercooler Hot air recirculation in front of intercooler Path Lines coloured by Temperature ( C) Wednesday, September 26, Automotive Simulation World Congress 20

21 Results: New Vehicle Baseline IRFM Packaging Intercooler Radiator Fan Module Wednesday, September 26, Automotive Simulation World Congress 21

22 Results: New Vehicle Improved IRFM Packaging IRFM Sealing Intercooler Radiator Fan Module introduced IRFM Sealing to stop hot air recirculation in under-hood compartment as shown in above fig. Wednesday, September 26, Automotive Simulation World Congress 22

23 Results: New Vehicle Under-hood Thermal Flow Field Baseline IRFM Packaging Improved IRFM Packaging Hot air recirculation in front of intercooler No hot air recirculation in front of intercooler Path Lines coloured by Temperature ( C) Wednesday, September 26, Automotive Simulation World Congress 23

24 Results: New Vehicle Power Condition Baseline IRFM Packaging Intercooler Improved IRFM Packaging Intercooler Velocity = 5.2 m/s Charged Air Flow direction Improved ambient air temperature profile at the intercooler inlet face Velocity = 5.2 m/s Charged Air Flow direction Wednesday, September 26, 2012 CFD T = 70.1 C 2012 Automotive Simulation World Congress CFD T = 78.5 C 24

25 Results: New Vehicle Power Condition Baseline IRFM Packaging Intercooler Improved IRFM Packaging Intercooler Velocity = 5.2 m/s Charged Air Flow direction Improved ambient air temperature profile at the intercooler inlet face Velocity = 5.2 m/s Charged Air Flow direction Wednesday, September 26, 2012 CFD T = 70.1 C 2012 Automotive Simulation World Congress CFD T = 78.5 C 25

26 Results: New Vehicle Power Condition Baseline IRFM Packaging Radiator Improved IRFM Packaging Radiator Coolant flow direction Velocity =7.3 m/s Improved ambient air temperature profile at the Radiator inlet face Coolant flow direction Velocity = 7.3 m/s CFD T = 5.9 C CFD T = 6.4 C Wednesday, September 26, Automotive Simulation World Congress 26

27 Results: New Vehicle Power Condition Baseline IRFM Packaging Radiator Improved IRFM Packaging Radiator Coolant flow direction Velocity =7.3 m/s Improved ambient air temperature profile at the Radiator inlet face Coolant flow direction Velocity = 7.3 m/s CFD T = 5.9 C CFD T = 6.4 C Wednesday, September 26, Automotive Simulation World Congress 27

28 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, Automotive Simulation World Congress 28

29 THANK YOU!! Contact: Ashok Patidar Wednesday, September 26, Automotive Simulation World Congress 29

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