Design Optimization of Engine Cooling System for Light Duty Diesel Engine for Weight and Cost Reduction Purpose

Engine cooling systems for vehicles are used for cooling the engine fluids. The cooling system normally consists of following components: radiator, expansion tank, cooling fan, fan drive and shroud. The mounting structure for this system must be designed to withstand the loads that will be imposed by the vehicle operation which consists of stresses such as those caused by linear static and dynamic loading. Automotive industries perform various tests on vehicles in the end-user environment to reduce failures; these investigations are carried out on the design using finite element method (FEM). Finite element methods are being used routinely to analyze for structural behavior. Modeling is done with CATIA software, meshing is carried out with HYPERMESH software and solution is acquired using NASTRAN solver. For linear static analysis, force was applied on the assembly using ‘g’ criterion, where g is the acceleration due to gravity and for linear dynamic analysis with forced vibration have used the frequency response along with enforced motion. For different analysis of vehicle condition, it is observed that design is safe for linear static and linear dynamic analysis. But for linear static even if design is safe, it that might fail during linear dynamic analysis.