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Simulation of engine cooling components within the development process of Behr STAR Global Conference 2012 Amsterdam, 2012-03-20

Simulation of engine cooling components within the ...mdx2.plm.automation.siemens.com/sites/default/...Simulation of engine cooling components at Behr Winglet tubes Development of

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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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t tra

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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

t tra

nsf

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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

nsf

er

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

9

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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

e #

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 [%

]

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)