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Simulation of engine cooling components within the development process of Behr
STAR Global Conference 2012Amsterdam, 2012-03-20
Simulation of engine cooling components at Behr
Systems
Underhood SimulationPrediction of available cooling air, flow and temperature distribution for components
CFD @ Behr Engine CoolingHeat Transfer & Flow Analysis
ModulesInteraction of heat
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
Interaction of heat exchangers, fan & blockage
ComponentsTrade Off for heat transfer & pressure loss
PartsOptimization of pressure loss & mass flow distribution
Simulation of engine cooling components at Behr
Parametric model setup
� Textfile with geometrical parameters (> 20) is input for automatic meshing� CAD data is not needed!
� Hexdominant mesh
� High resolution of BL
Winglet tubesOptimization of winglet geometry
gas flow
winglet.exewinglet.exe
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
Mesh & BCsMesh & BCs
STAR-CCM+STAR-CCM+
Simulation of engine cooling components at Behr
Winglet tubesAnalysis of boundary heat flux
gas flow
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
� Identification of areas of low and high heat flux at heat transfer boundary with respect to optimization of winglet design for increasing the heat transfer
Simulation of engine cooling components at Behr
Winglet tubes Development of optimized design
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Base
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
� Development of new winglet design with higher heat transfer at reduced pressure loss
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total pressure loss
Simulation of engine cooling components at Behr
Oil cooler platesOptimization of plate geometry
Base Variant
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
� Variation of plate geometry for optimization of heat transfer and reduction of pressure loss
� Possibility for meshing complex geometries by using STAR-CCM+
oil flow
Simulation of engine cooling components at Behr
Oil cooler platesAnalysis of boundary heat flux @ different operating points
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
oil flow
� Identification of areas of low and high heat flux at heat transfer boundary� Partially different behavior for different operating points
Simulation of engine cooling components at Behr
Oil cooler platesAnalysis of flow field @ different operating points
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
� Identification and optimization of flow pathes� Universal behavior (only minor dependence on operating point)
Simulation of engine cooling components at Behr
Oil cooler platesDevelopment of new plate design
hea
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BaseNew design variant
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
hea
t tra
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total pressure loss
� Development of new plate design with significantly reduced pressure loss and almost no reduction of heat performance
Simulation of engine cooling components at Behr
RadiatorPost Processing Parts for pressure loss and performance
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
∆T ∆p Location
- p2- p1 Inlet Hose
- p3 – p2 Inlet Tank
T3 - T2 p4 – p3 Core
- p5 - p4 Outlet Tank
- p6 - p5 Outlet Hose
Simulation of engine cooling components at Behr
Radiator Total pressure drop distribution
� Particular radiator with tubes of very short length
Inlet tank
Tubes
Outlet tank
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
Outlet tank
Inlet tank
� Visualization of inhomogenities of total pressure distribution within tanks and tubes
Simulation of engine cooling components at Behr
� The Arial font 14 shown here is used for copy texts.
� Please read „Information_english.pptx“ before you use the new presentation template for the first time!
RadiatorMass flow distribution of tubes
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Deviation from mean flux [%]
Uniformity Index
Base Design 0.9750
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
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Simulation of engine cooling components at Behr
RadiatorAnalysis of flow field in inlet tank for different meshes
Trimmed mesh Poly mesh
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
� Significant deviations in flow field in inlet tank for different meshes with reasonable number of cells
Simulation of engine cooling components at Behr
RadiatorDifferent meshing approaches
Manual Meshing: “Hexcore” meshTrimmed mesh Poly mesh
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
-15,0 -10,0 -5,0 0,0 5,0 10,0 15,0
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Tub
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Deviation from mean flux (%)
Deviation Row 1
-15.0 -10.0 -5.0 0.0 5.0 10.0 15.0
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Tub
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Deviation from mean flux (%)
Deviation Row 1
-15.0 -10.0 -5.0 0.0 5.0 10.0 15.0
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Tub
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Deviation from mean flux (%)
Deviation Row 1
� “Manual Hexcore Meshing” seems to combine advantages of Trimmed mesh and Poly mesh
Simulation of engine cooling components at Behr
Indirect Charge Air CoolerSimulation of Thermo Cycle Test (TCT)
Charge air
Coolant
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
� CFD Simulation for obtaining transient temperature distribution in solid
� FEA Simulation of TCT for identification of critical areas for part failure
Simulation of engine cooling components at Behr
� Comparison of experimental and numerical results for one cycle (heat up + cool down)
Indirect charge air coolerThermal shock and Thermography: Temperature sensors comparison with CFD
Experiment
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
Full Transient CFD “Temperature only“ CFD
Simulation of engine cooling components at Behr
� The Arial font 14 shown here is used for copy texts.
� Please read „Information_english.pptx“ before you use the new presentation template for the first time!
Indirect Charge Air CoolerThermal shock and thermography: Comparison thermography – “Temperature only“
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
Simulation of engine cooling components at Behr
Radiator / Indirect charge air coolerWorkflow of numerical simulation of TCT (CFD → FEA)
max.
FEA for thermal stress prediction
Mapping of transient solid temperature on FEA mesh
max.
min.
Transient CFD
t=10 s ->
<- t=4 s
Drawbacks (Potential):� Full CFD data required
for mapping (not only solids)
� Reloading of transient CCM files not possible
� Proximity check does not work
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
Lifetime Prediction Wöhler Curve /
Fatigue Software
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fitted curve lower 0.95 confidence limit upper 0.95 confidence limit lower 0.95 prediction limit upper 0.95 prediction limit
load cycles [-]
stre
ss le
vel [%
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CAC A CAC B
max.
min.� Turbulent flow for both fluids
� Conjugate heat transferto and from all solids
� Heat conduction in solids
Simulation of engine cooling components at Behr
Conclusionsand Outlook
� Variety of CFD simulation methods using STAR-CCM+ are established within the product development process
� High potential of automation and standardization by Java macro programming
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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.
Dr.-Ing. Stauch, March 2012
� Mapping process of post data in STAR-CCM+ not yet fully developed
� More meshing features are desired (e.g. partially structured meshes,“parallel wrapper”)
� Documentation of models and features has to be improved (e.g. Dual Stream HX - Actual flow)