The paper presents a combined experimental and numerical activity carried out to improve the accuracy of conjugate heat transfer CFD simulations of a high-performance S.I. engine water cooling jacket.
Due to the complexity of the computational domain, which covers both the coolant jacket and the surrounding metal cast (both head and block), particular care is required in order to find a tradeoff between the accuracy and the cost-effectiveness of the numerical procedure. In view of the presence of many complex physical phenomena, the contribution of some relevant CFD parameters and sub-models is separately evaluated and discussed.
Among the formers, the extent of the computational domain, the choice of a proper set of boundary conditions and the detailed representation of the physical properties of the involved materials are separately considered. Among the latters, the choice between a simplified single-phase approach and a more complex two-phase approach taking into account the effects of phase transition within the engine coolant is discussed.
The predictive capability of the CFD-CHT methodology is assessed by means of the comparison between CFD results and experimental measurements provided by the engine manufacturer for different engine operating conditions.
At the end of the validation process, a methodology for the correct and cost-effective characterization of conjugate heat transfer is proposed, showing a reasonable trade-off between the predictive capability and the computational effort of the simulations.