Structural and thermal behavior prediction of chiller by using CAE simulation

Heat exchangers are critical components in various industrial applications, enabling efficient energy transfer between fluids. Chiller (Plate-type heat exchanger), with its compact design and high thermal performance, have gained significant attention in industries such as HVAC, power generation, and chemical processing. This study presents a comprehensive thermo-structural analysis of a chiller generated due to varying fluctuating temperatures and vehicle vibrations using Computer-Aided Engineering (CAE) tools. The analysis involves modeling the heat exchanger geometry, including the alternate chiller plates, to capture the complex geometries. Advanced simulation techniques such as Computer- Aided engineering (CAE) and Finite Element Analysis (FEA) are employed to investigate the thermal behavior under varying operating conditions, including flow rates, inlet temperatures, and pressure drops. Key parameters like pulsation pressure test, temperature distribution, dynamic stress analysis, thermal stress analysis are evaluated to identify areas of improvement. This work demonstrates the capability of CAE tools in conducting accurate and efficient thermal analyses, offering a cost-effective alternative to experimental testing and paving the way for innovation in heat exchanger.