Charge air coolers for modern heavy duty Diesel direct injection (DI) engines have to he designed for increasingly critical loads, particularly due to severe temperature transients during operation. Reliable virtual functional assessment of the component design in early development phases is becoming a key competence in the design process. The paper describes a completely closed chain of computational fluid dynamics (CFD) and finite element analysis (FEA) simulation models for the transient aerothermodynamic and structural analysis of charge air coolers. Special emphasis is put on the numerical efficiency of the methodology and its thorough validation using test results. A completely closed chain of simulation models has been developed at BEHR, that allows the virtual aerothermodynamic and structural assessment of charge air cooler designs with respect to thermo shock load. The method is based on a transient CFD prediction of structure temperatures, their mapping onto a FEA mesh and the subsequent FEA prediction of stresses and strains in all locations in the cooler and at any time of a transient operation mode. The method accounts for charge air and cooling air side, heat transfer to, from and in all solids, including the fins, which are treated as homogenized media. A special two step procedure, utilizing different time step sizes for solving flow quantities and energy equation makes the methodology computationally efficient. This facilitates its application in tight schedule design processes, particularly in early development phases. The methodology has been validated using a large truck charge air cooler in a predefined test cycle that represents typical field load. The methodology is applicable also for in truck, in car application, e.g. based on data derived from an underhood simulation. Investigations of combined charge air cooler loads, e.g. from temperature transients and inner pressure, are also possible.


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    Title :

    Coupled aerothermodynamic and structural analysis of transient charge air cooler operation modes


    Additional title:

    Gekoppelte aerothermodynamische und Strukturanalyse der transienten Betriebsarten eines Ladeluftkühlers


    Contributors:
    Wetzel, T. (author) / Brotz, F. (author) / Löffler, B. (author) / Boerma, A. (author) / Fernandez, N. (author) / Heckenberger, T. (author)


    Publication date :

    2007


    Size :

    9 Seiten, 6 Bilder, 4 Quellen



    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English




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