Effective Utilization of a System Level Simulation Tool by Proper Selection of an Engine Radiator using the Validated Empirical cum Analytical Approach

The system level cooling simulation tools are used to reduce the number of experimental trials performed. Effectiveness of the simulation tools is largely dependent on the input given to the simulation program, these inputs are mainly the performance characteristics of the cooling system components that includes radiator, fan etc., of which the radiator characteristics are crucial and they decide the effectiveness of a simulation tool which in turn helps in reducing the number of field trials performed for engine cooling. Radiator characteristics generated thru different methods by different suppliers are frequently inconsistent. These different characteristics have to be compared on the same level for effective selection of radiators. As a vehicle manufacturer, this demands the common methodology to be created to overcome the inconsistencies in the process and thereby utilize the simulation tools effectively. In this study, an empirical-cum-analytical based methodology has been developed for generating the performance characteristics of the louvered fin heat exchanger using the thermal resistance and Number of Transfer Units (NTU) method. This methodology was validated with the experimental data for an engine cooling radiator. The experimental approach involved selecting a radiator and subjecting it to a wind tunnel test for different air and coolant flow. Using these component characteristics, radiators of different manufacturer and specifications can be effectively and consistently compared. Radiator characteristics generated thru this validated methodology has been used for performing system level cooling simulation using the one-dimensional software KULI and results of this simulation has been validated with the engine cooling test for two such different combinations. Methodology validation thru component wind tunnel test and system level simulation validation thru engine test bed cooling trials ensures the number of in-vehicle test trials performed for replacing/selecting the radiators reduces, thereby reducing the product development lifecycle cost, and time.