Wall Temperatures and Airflow Prediction in Automotive Headlights Utilizing the CFD Methodology

Nowadays the increase and maintenance of a car manufacturer market share is greatly influenced by the appeal its products design, wherein the headlights occupy a distinctive position. However, the headlights designers' constant search for newer and innovative designs sometimes yields difficulties regarding the thermal management of these components, requiring cautious material selection, and special care in the parabolas dimensioning and positioning of bulbs and vents in the case.

This work shows how a simulation strategy based on the finite volume method can be utilized to predict the headlight airflow and plastic walls temperature distribution induced by the bulbs thermal radiation. The main goal of this modeling is to raise and treat potential temperature issues early in the development cycle, guiding the corrective design actions, and supporting the material selection and specification process.

The earlier evaluation of the air flow behavior inside the case also allows the improvement of the vents performance, providing valuable information for the treatment of the condensation within the case. This methodology has been validated against physical measurements presenting good agreement.