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Virtual Temperature Cycle Test (TCT) for Validation of Indirect Charge Air Coolers & Exhaust Gas Recirculation Coolers
MAHLE Behr has developed a standardized workflow for simulating a virtual Temperature Cycle Test (TCT). This test is an integral part in the development process of indirect Charge Air Coolers (iCAC) and Exhaust Gas Recirculation coolers (EGR). Within this test, the cooler is charged with an alternating high and low heat load by varying the hot gas temperature and mass flow rate. The transient CFD simulation is performed with STAR-CCM+ to model the flow of the fluids inside the cooler, the convective heat transfer between the fluids and the solid and the heat conduction within the solid. The...
Simulation of the Interior Cabin Warm-Up & Cool Down using CFD
In a passenger vehicle it is essential the ventilation system is designed to deliver air at the correct flow and temperature levels to keep the occupants comfortable. To create such an environment it is essential the climate control system is designed correctly to meet the demands of cooling and warming up of the cabin. To be able to design such systems with shortened vehicle programme times and reduced number of early physical prototypes, virtual simulations are required. The simulations must be able to predict accurately the flow and thermal behaviour through the ventilation system and into...
Simulation of a Hydraulic Cam Phaser
In engines destined for use in Mercedes-Benz passenger cars, the phasing of the camshafts is regulated with hydraulic cam phasers. New engine applications in conjunction with higher expectations relating to the performance of the adjustment increasingly require the optimization of the oil circulation in the system. The cam phasers currently used work on the swivel-vane/swivel-motor principle. The system to be simulated includes the oil circulation in the camshaft bearings, the central valve integrated in the adjuster and the adjuster with hydraulic lock. The tasks to be resolved in order to...
Simulating Systems in Ground Vehicle Design
CD-adapco has been involved with simulation in the ground transportation industry for nearly a third of a century. Initially, simulation was used solely to investigate the cause of a failure. Models were fairly simple that looked only at a specific features of the design, for example to ensure that coolant flow reached the critical areas of an engine design (most likely one that had failed on the testbed). Today the role of simulation is more mature, and allows engineers to analyze the performance of entire systems of components, operating under real life scenarios - such as a vehicle towing...
Racecar Rear-Wing Setup Optimization via 2D CFD Simulations
ART Grand Prix, a motorsport company based near Paris in France, is committed to the highest level of motorsport. Competing actively in GP2, GP3 and GT championships, this team has built a strong palmares over the last decade. Some of their former drivers, like Sebastian Vettel and Lewis Hamilton, subsequently became world champions in Formula 1. Without denying the talent of the drivers, their success is not only due to them. Behind these victories and these titles, there is a team of mechanics and engineers dedicated to extracting the best from the cars while respecting the technical,...
Practical CFD-DEM Software Needs & Issues in Agricultural Crop Flow Modeling
Manufacturers of agricultural combines and harvesting equipment have a special need to model non-spherical solid particles in gas flows usually in combination with complex moving wall boundaries and and extremely complex geometry. Over the years STAR-CCM+ has made great strides towards producing an ideal tool for use in developing agricultural harvesting equipment but with a few typical examples of agricultural flows of interest, features still badly needed for this type of product development will be demonstrated.
CFD Topological Optimization of a Car Water-Pump Inlet using TOSCA Fluid & STAR-CCM+
Problem: Often an engine should fit into several vehicle applications, requiring that some parts have to be modified to match all package configurations. Driven by such package constraints, an inlet pipe to the water-pump inlet had to be redesigned resulting in a 180 degree coolant direction change in front of the water pump inlet. In the beginning the U-flow shaped design was generating an inhomogeneous and non-uniform inlet flow at the water-pump entry. This will reduce the water-pump efficiency and might cause cavitation at the impeller. Solution: For this case the first-in-industry...
Analysis of the Lubrication System in a High Pressure Piston Water Pump
The thermal analysis has a key role in piston water pump design; in fact, the pumps have to endure long time operation and the lubrication system has to accomplish the task of both reducing the friction between moving components and to transfer the heat produced by the frictions in order to avoid overheating. The lubricating and cooling effects depend on a number of parameters of the lubricating system, such as the amount of oil in the crank case and the material and the geometry of the components; selecting the best configuration for all the pump operating conditions is a challenging...
A Numerical Approach to Thermal Management of Dynamic Driving Cycles
Vehicle thermal protection has become more important than ever in the vehicle development process. Harsher emission standards and improved fuel economy driven by legislation weighs against the driver’s desise for cars with good driving performance. These challenges are driving development towards compact engine layouts with higher specific engine performance. In addition, a tighter packaging of the exhaust system next to the engine is causing higher thermal loads in the engine compartment. The major aim of thermal protection is to ensure that all components inside the vehicle stay well below...
Progress in Tools for Turbulence Modelling and Simulation
Hybrid RANS-LES methods can be very useful when high detailed insight into turbulent flow is required, in which instantaneous fluctuations play a critical role. For example when a high-accuracy prediction of complex flow separation is needed, or for insight into thermal fatigue due to fluctuating flows at different temperature, or for the approximation of acoustic noises levels via measurement of fluctuating pressure. Compared to the full deployment of Large Eddy Simulation (LES), the Hybrid methods are designed to retain an economical RANS turbulence model in regions where they are expected...

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