Presented at the STAR Global Conference 2012
Behr is using various CFD simulation processes and methods within the development process of components for engine cooling applications. In the future STAR-CCM+ is going to be the standard tool for CFD simulations.
The biggest challenges within these simulation processes are the stability and robustness of the simulations including the distribution of flow and temperature fields into the fluid as well as the temperature distribution in the adjacent solid. Due to the application of the methods within the standard development process, simulation times are of great importance.
The flow of coolant within a radiator and the flow of charge air within a charge air cooler (CAC) is simulated. Radiators as well as charge air coolers consist of a block of several heat transferring tubes together with an inlet and an outlet tank. The pressure drop distribution of the different parts like blocks and tanks of the cooler and the mass flow distribution of the individual tubes of the block are analyzed. Indirect charge air coolers (iCAC), consisting of tanks and stacked plates, are simulated including the charge air flow, the coolant flow and the solid parts representing the cooler itself.
Besides the pressure drop distribution and the mass flow distribution of the individual plates, the temperature distribution of the solid parts are obtained by the CFD simulation and later mapped to FEA models to analyze thermal stresses. Furthermore, several detail simulations of single elements of cooling components like tubes, fins or plates are performed to optimize them..