Sizing of Coolant Passages in an IC Engine Using a Design of Experiments Approach

Determining coolant flow distribution in a topologically complex flow path for efficient heat rejection from the critical regions of the engine is a challenge. However, with the established computational methodology, thermal response of an engine (via conjugate heat transfer) can be accurately predicted [1, 2] and improved upon via Design of Experiment (DOE) study in a relatively short timeframe. This paper describes a method to effectively distribute the coolant flow in the engine coolant cavities and evenly remove the heat from various components using a novel technique of optimization based on an approximation model. The current methodology involves the usage of a sampling technique to screen the design space and generate the simulation matrix. Isight, a process automation and design exploration software, is used to set the framework of this study with the engine thermal simulation setup done in the CFD solver, STAR-CCM+. This is followed by the construction of a approximation model which aids in evaluating the interaction between the design variables (coolant passage dimensions). The methodology utilized here enables the prediction of the thermal map of the engine in the early stages of design and minimizes the need for expensive hardware testing, thus reducing the product development cycle time and cost.