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Engine Cooling: " Latest Trends in Design & Development of I.C.Engines "
Engine Cooling: " Latest Trends in Design & Development of I.C.Engines "
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
The Cooling System
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Contents
Functional requirements
Modern Techonologies
Failure modes
Analysis tools
Design validation tools
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Functional Requirements
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Modern Techonologies
Underhood temperatures
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Tracking the Fuel Energy - Naturally Aspirated
Pumping work
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Failure Modes
Thermal fatigue
Cylinder heads
Pistons
Head gaskets
Exhaust manifolds
Lubricant breakdown
Ring deposits
Valve sticking
Reduced oil drain interval
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Component Thermal Loading Issues
1. Cylinder Head
Cylinder head thermal fatigue
Severe temperature gradients
Potential for yielding in valve bridges
Controlling gradients is often as important as controlling
maximum temperature
Proving durability is extremely difficult
Aggressive thermal cycles may drive cracking, but design
changes to eliminate the cracks do not necessarily prove the
design
Careful, validated FE analysis, used in conjunction with
historical database, is recommended
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Component Thermal Loading Issues
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Component Thermal Loading Issues
3. Piston and Rings
Thermal fatigue of piston crown
Gradients not as severe, but aluminum fatigue strength
drops rapidly with temperature
Thermal cycle testing, in conjunction with FE analysis to
validate durability
Undercrown
Thermal loads contribute to pin boss cracking
Undercrown oil coking
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Component Thermal Loading Issues
4. Cylinder Wall
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Cooling Circuit
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Cooling Circuit
a. Series Flow
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Cooling Circuit Parallel Flow
b. Parallel Flow
Longer warm-up
Control over block and
head proportions
Minimal external plumbing
in transverse installations
Reduced pressure drop
Reduced coolant
temperature to head
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Cooling Circuit
c. Cross Flow
Low pressure header
Excellent cylinder
balance
Complex jackets limited Thermostat
to larger engines
Inlet and outlet can be at
either end of engine
Increased cost
Increased warm-up time
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Meeting Cylinder Circumferential Temperature
Requirements
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Cylinder Jacket Considerations
Open versus Closed Deck
Temperature control at TRR
Cylinder distortion
Head gasket sealing
Goals
Sufficient velocity in
critical regions
Velocities not too high
erosion, especially with
aluminum
Avoid stagnant regions
Coolant volume low for
rapid warm-up
Venting
Design Levers
Flow driven by
Pressure differential
Restriction
Velocity increased by
reducing flow area
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Cylinder Cooling Jacket Length
Concerns
Increased heat rejection to oil
Reduced volumetric efficiency
Resulting piston and ring temperatures
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Water Pump and its Design
Water Pump Function:
To provide an appropriate coolant flow rate through the engine to
remove the excess energy of combustion for maintaining engine
temperature.
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Water Pump Design Flowchart
No. of vanes
Calculation of Required
water flow from Heat Outlet Vane Width
Balance Sheet
Check for
Diameter
Pump Head is decided Ratio
based on Bench-marked
data.
Outlet Vane Angle Outlet Vane Diameter
Pump Speed is finalized.
Peripheral Velocity at
Pump Specific Speed Outlet
Hydraulic Efficiency
Shaft Power HUB Diameter
Volumetric Efficiency
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Algorithm for Water Pump Design
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Algorithm-CAD software Interface
Interface between Algorithm and CAD software
helps in Rapid Product Development
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Pump CAD Models
C/S of Single-Arc
Volute Volute Impeller Vane
Curve
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Component Temperature Control
Coolant required to control Wall temperature undergoes small
temperatures at critical points for swing on combustion chamber
durability and oil control. In spark- surface through engine operating
ignition engines knock margin is cycle.
also influenced. 15-20 oC cast iron
8-10 oC aluminum
450
350
250
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Circuit Modeling
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
CFD as a Development Tool
Cooling System
CFD is used to evaluate:
Energy losses
Flow distributions and coolant velocity at critical locations (e.g.
injector, valve bridges, etc.)
Provide boundary conditions for structural analysis
Typical components:
Cylinder heads and blocks
Oil coolers, thermostat housings, water pumps, etc.
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
CFD as a Development Tool
Cylinder Blocks and Heads
Results
Flow distributions through system
Velocities at critical locations
Pressure drops
Heat transfer coefficients for
structural Analysis
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
CFD as a Development Tool
Water Pump
Spatial Distribution of Coolant Temperature Along Cutting Plane Y
Flow Separation
Zones
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Design Validation Tools
Flow visualization
Bench tests
Water pump mapping
Deaeration
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Flow Visualization
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Water Pumps Testing
Pressure Head
Inlet and outlet pressure
Efficiency
Cooling system
Air entrainment and characteristic
cavitation
Coolant Flow Rate
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Filling, Venting, and Deaeration
Baffle
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Conclusions
Downsizing Trend of engines is putting heavy demand in
optimum design of cooling circuit which comprises of
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LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES