Validation of Finite Element (FE) Model for All Aluminum Radiator End Tank

Aluminum Radiator end tank is simulated for internal static pressure using Finite Element Analysis technique. Strain gage testing is done on the actual tank to collect strain data. Strain data from Finite Element results and the collected test data are compared to validate the brazing methodology used to simulate the brazed joint between various components. Also, pressure cycle test on the radiator end tank is simulated using Finite Element method. Radiator Tank consists of various components, which includes header, outlet tube, tank top and sides brazed together in the furnace at elevated temperatures. Separate Finite Element model is created for each individual component and joined together simulating appropriate brazed joints to perform the pressure cycle test. Constrain Equation Technique has been used to simulate the brazed joint and will be discussed in this paper.

Also, included in the simulation is the extension of Radiator end tank to include core with fin & tube assembly. To reduce the size of the model for computation, partial finite element model of Radiator core consisting of fin & tube assembly is included with symmetric boundary conditions to simulate continuity of the model along the length of the tube. Tank and fin & tube assembly is subjected to known internal static pressure. Initially, linear analyses have been conducted to check the validity of the Finite Element model. Later, Nonlinear analyses have been conducted to include the material nonlinearity at elevated temperatures.