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Use of STAR-CCM+ for Heat Exchanger Product Development
The presentation will demonstrate the use of STAR-CCM+ to help develop a new type Charge Air Cooler (CAC) for heavy duty off-highway applications. A fin-tube type cross flow CAC requires very small mesh size in CFD model to capture its fin geometric characteristics and resolve the thermal boundary layer. Hundreds of millions of cells may be generated in the CFD model for a Conjugated Heat Transfer (CHT) study of the whole CAC unit, which will then require huge computing resources and make the CFD study very inefficient. The single and dual stream heat exchanger models in STAR-CCM+ require the...
Thermal Analysis & Design Improvement of an Internal Air-Cooled Electric Machine
Conjugate Heat Transfer analysis is performed on a split phase induction motor with internal fan-driven air-cooled topology by using the electromagnetic losses computed in SPEED and mapping them onto the real-world 3-D geometry in STAR-CCM+. Temperature dependent copper losses (I^2R) are modeled in both the stator winding and the aluminium rotor squirl cage. Simulation and measured temperatures are compared to show accuracy of this process. An improved, "vented" stator geometry is swapped into the STAR-CCM+ simulation to determine the potential impact of this design change upon the machine's...
Heat Transfer Through an Axial Fan with a Non-Homogeneous Temperature Source
Thermal protection is an important task in the development process of Mercedes Benz. Therefore a combination of heat exchangers and fans are applied for engine cooling. In some cases the set-up of fan and heat exchangers can cause a flow field, in which the temperature and velocity are strongly non-homogeneous in front of the engine fan. Under these conditions the thermal behaviour of the axial fan cannot be simulated in a proper way with the commonly applied quasi-steady Multiple Reference Frame model (MRF). For a reliable prediction of the thermal behaviour unsteady numerical simulations or...
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...

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