Browse Topic: Computational fluid dynamics (CFD)

Items (4,310)
This study introduces a computational approach to evaluate potential noise issues arising from liftgate gaps and their contribution to cabin noise early in the design process. This computational approach uses an extensively-validated Lattice Boltzmann method (LBM) based computational fluid dynamics (CFD) solver to predict the transient flow field and exterior noise sources. Transmission of these noise sources through glass panels and seals were done by a well-validated statistical energy analysis (SEA) solver. Various sealing strategies were investigated to reduce interior noise levels attributed to these gaps, aiming to enhance wind noise performance. The findings emphasize the importance of integrating computational tools in the early design stages to mitigate wind noise issues and optimize sealing strategies effectively.
Moron, PhilippeJantzen, AndreasKim, MinsukSenthooran, Sivapalan
The advancement of civil supersonic aircraft is significantly constrained due to the intense noise generated by the shock waves that form during cruise, commonly referred to as the sonic boom. Due to these excessive noise levels, regulatory authorities currently ban supersonic flights over land. This study presents a comprehensive methodology to evaluate sonic booms in mid- and far-field regions, starting with a precise estimation of the near-field pressure signature produced by the shock wave system. While high-fidelity computational fluid dynamics (CFD) techniques typically provide near-field sonic boom predictions, specific propagation models must be used at greater distances, as CFD becomes prohibitively expensive beyond approximately 10 km. The focus of this research is a comparative analysis of a low-fidelity propagation approach, such as Whitham’s equation, and a high-fidelity CFD-based approach for assessing sonic boom propagation over medium range distances. The low-fidelity
Glorioso, AntimoFasulo, GiovanniPetrosino, FrancescoBarbarino, Mattia
The ported shroud casing treatment for turbocharger compressors is desirable for mitigating broadband/whoosh noise and enhancing boost pressures at low to mid flow rates. Yet, it is accompanied by elevated narrowband noise at the blade-pass frequency (BPF). Compressor BPF noise occurs at high frequencies where wave propagation is often multi-dimensional, rendering traditional planar wave silencers invalid. An earlier work introduced a novel reflective high-frequency silencer (baseline) targeting BPF noise in the 8-12 kHz range using an “acoustic straightener” that promoted planar wave propagation along arrays of quarter-wave resonators (QWRs). The design, however, faced challenges with high-amplitude tonal noise generation at specific flow conditions due to flow-acoustic coupling at the opening of the QWRs, thereby compromising the noise attenuation. The current study explores two QWR interface geometries that weaken the coupling, including linear and saw-tooth ramps on the upstream
Sriganesh, PranavSelamet, Ahmet
Wind noise is one of the largest sources to interior noise of modern vehicles. This noise is encountered when driving on roads and freeways from medium speed and generates considerable fatigue for passengers on long journeys. Aero-acoustic noise is the result of turbulent and acoustic pressure fluctuations created within the flow. They are transmitted to the passenger compartment via the vibro-acoustic excitation of vehicle surfaces and underbody cavities. Generally, this is the dominant flow-induced source at low frequencies. The transmission mechanism through the vehicle floor and underbody is a complex phenomenon as the paths to the cavity can be both airborne and structure-borne. This study is focused on the simulation of the floor contribution to wind noise of two types of vehicles (SUV and Sports car), whose underbody structure are largely different. Aero-Vibro-acoustic simulations are performed to identify the transmission mechanism of the underbody wind noise and contribution
Mordillat, PhilippeZerrad, MehdiErrico, Fabrizio
During the last decades there has been a renewed interest in the development of a new generation of supersonic aircraft for civil purposes with limited implications to the environment. However, the noise generated by supersonic aircraft during supersonic flight, commonly referred to as "sonic boom", still creates annoyance to community on the ground that prohibits supersonic overland flight. To prepare for the advent of a new generation of supersonic aircraft and to define new regulations for them, an increasing number of sonic boom studies is being published. This paper presents numerical simulations of the sonic boom of a hypersonic (Mach 5) aircraft concept during the full flight envelope, including a sensitivity analysis of the two parameters velocity and altitude. The extensive simulations characterize the sonic boom distribution on ground, which is usually referred to as “sonic boom carpet”, caused by the aircraft for different speeds between Mach 1.2 and Mach 5.0, and for two
Graziani, SamueleJäschke, Jacob JensViola, NicoleGollnick, Volker
This paper presents a fully parallelized Computational Acoustics (CA) module, integrated within the Simerics-MP+ platform, developed for the prediction of noise source power and far-field propagation across a range of Computational Fluid Dynamics (CFD) applications. Utilizing the Ffowcs Williams-Hawkings (FWH) acoustic analogy, the CA module seamlessly integrates with existing CFD workflows, offering minimal computational overhead with less than a 5% increase in runtime. Extensive validation has been conducted against analytical, numerical, and experimental data in various acoustic scenarios, including monopole and dipole noise emissions, flow around slender bodies, circular cylinders and aero-propellers. These validation studies underscore the reliability of the framework in accurately identifying noise sources and assessing the impact of design modifications, significantly reducing the need for expensive physical prototyping in industries such as automotive and aerospace. Building
Taghizadeh, SalarCzwielong, FelixBecker, StefanVarghese, JoelRaj, GowthamDhar, Sujan
Large eddy simulations (LES) of two HVAC duct configurations at different vent blade angles are performed with the GPU-accelerated low-Mach (Helmholtz) solver for comparison with aeroacoustics measurements conducted at Toyota Motor Europe facilities. The sound pressure level (SPL) at four near-field experimental microphones are predicted both directly in the simulation by recording the LES pressure time history at the microphone locations, and through the use of a frequency-domain Ffowcs Williams-Hawking (FW-H) formulation. The A-weighted 1/3 octave band delta SPL between the two vent blades angle configurations is also computed and compared to experimental data. Overall, the simulations capture the experimental trend of increased radiated noise with the rotated vent blades, and both LES and FW-H spectra show good agreement with the measurements over most of the frequency range of interest, up to 5,000Hz. For the present O(30) million cell mesh and relatively long noise data collection
Besem-Cordova, Fanny M.Dieu, DonavanWang, KanBrès, Guillaume A.Delacroix, Antoine
When a vehicle is driven at high speed, there exists intricate flow pattern and vortex shedding at the side window area with intense pressure fluctuation. A significant dynamic pressure difference between the vehicle's exterior and interior can render the side window sealing system vulnerable to aspiration. This susceptibility can lead to the generation of leakage noise, adversely affecting acoustic comfort in the vehicle's cabin. This paper delves into the aspiration properties of glassrun seal system under time-varying pressure difference. A nonlinear finite element model of the glassrun seal was established to simulate the quasi-static deformation of the sealing strip during installation process, which aims to obtain the deformed geometric shape and residual stress after this process. Then, the exterior flow field of the glassrun sealing area of a simplified vehicle model was calculated with CFD simulation to obtain the hydrodynamic pressure excitation acting on the outer surface of
Li, HanqiHe, YinzhiZhang, LijunZhang, YongfengYu, WuzhouJiang, ZaixiuBlumrich, ReinhardWiedemann, Jochen
Within automobiles, the HVAC is a critical system to regulate the occupants’ thermal comfort. However, at its high operating speeds, it can contribute significantly to the overall sound levels perceived by the cabin occupants, impacting their experience. This is especially true in the case of electric vehicles due to their overall quieter operation. This work has the intention to validate HVAC noise predictions using computational fluid dynamics (CFD) simulations. In addition, CFD simulations provide detailed flow field insights which are essential to identify and rank the main noise sources, and it ultimately allows a better understanding of the physical mechanisms of noise generation on similar systems. These insights are very difficult, if not impossible, to obtain with physical testing and are key to designing a quiet and efficient HVAC system. Sound levels were measured experimentally at eight different locations inside of a Class-8 Nikola TRE hydrogen fuel cell electric semi
Ihi, RafaelFougere, NicolasPassador, StephenWoo, SangbeomKim, JamesDesouky, Mohamed
Improving electric vehicles’ overall thermal management strategy can directly or indirectly improve battery efficiency and vehicle range [1]. In this study, the effect of the coolant type used in BTMS (battery thermal management system) units used for heating batteries in cold weather conditions was investigated in electric buses. In this investigation, tests were performed with two types of antifreeze, which have different characteristics. The study evaluated the impact of coolant flow, BTMS circulation pump performance, and battery heating using these two types of antifreeze in the BTMS coolant line. In addition to carrying out tests, 1D computational fluid dynamics models’ simulations were carried out for both types of antifreeze, and the results were validated with experimental findings. In this study, a 12-m EV Citivolt vehicle of Anadolu Isuzu was used for tests. As a result, it was observed that differences in the properties of the antifreeze that is used in BTMS coolant line
Çetir, ÖzgürBirgül, Çağrı Emre
Wind noise is an important indicator for evaluating cabin comfort, and it is essential to accurately predict the wind noise inside the vehicle. In the early stage of automotive design, since the geometry and properties of the sealing strip are often unknown, the contribution of the sealing strip to the wind noise is often directly ignored, which makes the wind noise obtained through simulation in the pre-design stage to be lower than the real value. To investigate the effect of each seal on wind noise, an SUV model was used to simulate the cases of not adding body seals, adding window seals, and further adding door seals, respectively. The contribution of each seal to wind noise was obtained and verified by comparing it with the test results. The influence of the cavity formed at the door seal was also addressed. In the simulations, a CFD solver based on the lattice Boltzmann method (LBM) was used to solve the external flow field, and the noise transmitted into the interior of the
Zhang, YingchaoHe, TengshengWang, YuqiNiu, JiqiangZhang, ZheShen, ChunZhang, Chengchun
Since proportion of wall heat loss takes as high as 20-30% of the total engine heat loss, the reduction of wall heat loss is considered as an effective way to improve the engine thermal efficiency. The heat transfer near the wall boundary layer plays a significant role on the exploration about the mechanism of wall heat transfer which contributes to figuring out the approach to the reduction of wall heat loss. However, the near wall characteristics of heat transfer are still unclear. In this study, the premixed lean methane flame propagation was captured by the high-speed schlieren and the flame behavior in the near-wall region was investigated by the micro CH* chemiluminescence. The temporal histories of the wall temperature and the heat flux are measured by the co-axial thermocouple. The factors including the convective heat transfer coefficient and non-dimensionless numbers, Nusselt number and Reynolds number, were used to characterize the near wall characteristics. Also, the
Xuefeng, XueRun, ChenTie, Li
The rise of electric vehicles (EVs) highlights the need to transition to a renewable energy society, where power is generated from sustainable sources. This shift is driven by environmental, economic, and energy security concerns. However, renewable energy sources like wind and solar are intermittent, necessitating extensive energy storage systems. Vanadium redox flow batteries (VRFBs) are promising for large-scale energy storage due to their long cycle life, scalability, and safety. In VRFBs, cells are typically connected in series to increase voltage, with electrolytes introduced through parallel flow channels using a single manifold. This design, while simple and low in pressure drop, often leads to imbalanced flow rates among cells, affecting performance. Balancing flow rates is crucial to minimize uneven overpotential and enhance durability, presenting an optimization challenge between achieving uniform flow and minimizing pressure drop. This study developed numerical models to
Suwanpakdee, NutAiemsathit, PorametCharoen-amornkitt, PatcharawatSuzuki, TakahiroTsushima, Shohji
The future potential of an opposed-piston two-stroke (OP2S) engine has attracted the attention of researchers worldwide as it offers a high thermal efficiency and power-to-weight ratio with a simple engine configuration. This engine can be used with low-carbon fuels and hydrogen to reduce greenhouse gas emissions. However, the two-stroke operation has always been limited by its low scavenging efficiency and short-circuit of fresh charge. The current work is focused on optimizing scavenging efficiency and short-circuit in a small 200 cc single-cylinder OP2S SI engine using 3-D computational fluid dynamic (CFD) simulations. The effect of four parameters, namely, area of intake ports, area of exhaust ports, and angular orientations of intake ports (swirl and tilt) on scavenging efficiency and short-circuit, has been assessed and optimized. A Latin-hypercube based Design of Experiments (DoE) methodology is used to sample the design space spanning over a range of four parameters. A response
Singh, SaurabhBoggavarapu, PrasadHimabindu, M.Ravikrishna, R.V.
Swirl chamber combustion system is commonly used for IDI (In-Direct Injection) diesel engine. It is characterized by swirl combustion chamber arranged in cylinder head, main combustion chamber with shallow piston recess and connecting throat where fuel spray and flame mixture is ejected out from the swirl chamber to the main chamber [1]. Fuel is supplied in the swirl chamber and a pintle type nozzle is often used in this type engine as its simple structure and robustness for operating condition. In this paper, numerical simulation of a pintle nozzle spray was focused on and simulated results were compared with high speed photo data obtained in a constant volume vessel (CVV). Spray angle and tip penetration were mainly evaluated, but simulated angle and penetration could not be matched simultaneously to these characteristics of the pintle nozzle spray when conventional spray models were used for the simulation. To overcome this mismatch, “Multi-hole replacement model” was newly
Okazaki, TadaoFujiwara, Tsukasa
The growing demand for sustainable transportation solutions and renewable energy storage systems has heightened the necessity for precise and effective prediction of battery thermal performance. However, achieving both precision and efficiency poses a challenge, necessitating exploration into diverse methodologies. The conventional use of Computational Fluid Dynamics (CFD) offers a comprehensive insight into thermal dynamics but prioritizes precision over efficiency. To enhance the efficiency of this traditional approach, numerous reduced-order modeling techniques have emerged, and the concept of Machine Learning (ML) presents a distinct avenue for enhancing simulation capabilities, particularly in the context of mobility solutions. This paper presents a novel approach to accelerate battery thermal analysis by integrating CFD and ML. The CFD simulations provide an intricate understanding of the thermal dynamics within batteries, encompassing fluid flow and temperature distributions
Devarajan, GurudevanVaidyanathan, GaneshBhave, AjinkyaJi, LichaoWang, JiaoZhou, WeiHe, JiguangShi, Pengfei
In recent years, climate change and geopolitical instability have intensified the focus on sustainable power generation. This shift seeks alternatives that balance environmental impact, cost-effectiveness, and practicality. Specifically, in transportation and power generation, electric motors face challenges against internal combustion engines due to the high cost and mass of batteries required for energy storage. This makes electric solutions less favorable for these sectors. Conversely, internal combustion engines, when properly fueled, offer cost-effectiveness and a quasi-environmentally-neutral option. To address these challenges, researchers have explored e-fuels derived from renewable sources as a carbon-neutral supply for internal combustion engines. Among these, hydrogen is particularly promising. In hydrogen-powered internal combustion engines, 3D-CFD (Computational Fluid Dynamics) in-cylinder models are crucial. Once validated, these models can speed up the design process. A
Sfriso, StefanoBerni, FabioBreda, SebastianoFontanesi, StefanoCordisco, IlarioLeite, Caio RamalhoBrequigny, PierreFoucher, Fabrice
The Electric Control Unit (ECU) is a crucial computing unit responsible for engine regulating various functions. However, non-airflow thermal design due to the complexity of engine bay turbulent flow simulation is limiting ECU’s potential with the increasing demand of computation power consumption, thermal design faced additional challenges. Moreover, the lack of standardized ECU design guidelines forced substantial investments in customized thermal solutions for different engine bay packaging. Through this research, the method of finding representative points of ambient temperature efficiently and reliably is investigated, so that thermal design can be achieved by estimating flow properties during the ECU design stage efficiently. This research involves studying the effects of airflow on ECU cooling using experimental and numerical analysis in Computational Fluid Dynamics (CFD). Alongside the representative points of ambient temperature uncovered from the numerical result
Zhong, JiajunInaba, KazuakiYamaguchi, RyotaYasui, RyutaUmeno, Masafumi
Thermal runaway in battery cells presents a critical safety concern, emphasizing the need for a thorough understanding of thermal behavior to enhance battery safety and performance. This study introduces a newly developed AutoLion 3D thermal runaway model, which builds on the earlier AutoLion 1D framework and offers significantly faster computational performance compared to traditional CFD models. The model is validated through simulations of the heat-wait-search mode of the Accelerating Rate Calorimeter (ARC), accurately predicting thermal runaway by matching experimental temperature profiles from peer-reviewed studies. Once validated, the model is employed to investigate the thermal behavior of 3D LFPO cells under controlled heating conditions, applying heat to one or more surfaces at a time while modeling heat transfer from non-heated surfaces. The primary objective is to understand how these localized heating patterns impact temperature profiles, including average core temperatures
Hariharan, DeivanayagamGundlapally, Santhosh
In driving condition, the electric drive system of electric vehicles generates significant heat, which increases temperature of the motor, leading to reduced performance and energy loss. To manage the motor temperature and recover energy, a plate-fin heat exchanger (PFHE) is used to facilitate heat exchange between the electric drive system and the vehicle's thermal management system. In this study, Computational Fluid Dynamics (CFD) method was used to investigate the fin structure on thermal flow performance within the PFHE. The mathematical models of pressure drop and heat transfer of plate-fin heat exchanger are established in this paper, and an empirical formula for the friction factor was derived by using test data. The NTU method was applied to fit the formula of convective heat transfer coefficient, enabling the derivation of an empirical formula for the Colburn factor. A CFD simulation model was developed for a local heat exchange unit, considering the generic boundary
Yin, JintaiYin, ZhihongLu, XuanWang, MengmengLiu, Qian
The advancement of automotive industry demand compact size of HVAC with better cabin comfort. To achieve this, HVAC has to be optimized in all the aspects such as in shape & size, thermal comfort as well as in noise comfort. from an HVAC perspective, aeroacoustics noise is more significant due to its intensity at higher speeds and frequencies. Since HVAC is mounted inside the cabin, noise can transfer directly inside cabin. To avoid this, noise reduction or noise controlling is of very important. This is possible with HVAC design and simulation at the initial level and acoustic prediction after the CFD/CAA analysis. The present paper describes the aeroacoustic simulation of one of the HVAC to predict the noise during face mode. For that, 1-D simulation has been done initially to find the porosity of heat exchangers and coupled with a CFD solver. STAR CCM+ software is used for the CFD analysis. Transient simulation is performed with compressible fluid using a moving mesh approach. To
Kame, ShubhamParayil, PaulsonGoel, Arunkumar
In this paper, the topology and shape optimization of a vehicle Heating, Ventilation, and Air Conditioning (HVAC) system is presented. The CFD and optimization methodologies are implemented within AcuSolve™ software. The topology optimization algorithm computes the geometry, where the design domain is parameterized with a field of porosity design variables which indicates the material, fluid or solid, throughout the domain. The optimization is performed using the continuous adjoint approach by the Galerkin Least Squares solver on which the AcuSolve™ solver is based. The design is further improved by using shape optimization. To optimize the geometrical shape, a combination of smooth perturbations, in terms of so called morph shapes, are used to deform the geometrical shape in the optimization algorithm. To this end, a parameterization of the design space is done using a moderate number of design variables, each associated with a morph shape. The two optimization phases are connected by
Papadimitriou, DimitriosSandboge, Robert
The vehicle wake region is of high importance when analyzing the aerodynamic performance of a vehicle. It is characterized by turbulent separated flow and large low-pressure regions that contribute significantly to drag. In some cases, the wake region can oscillate between different modes which can pose an engineering challenge during vehicle development. Vehicles that exhibit bimodal wake behavior need to have their drag values recorded over a sufficient time period to take into account the low frequency shift in drag signal, therefore, simulating such vehicle configurations in CFD could consume substantial CPU hours resulting in an expensive and inefficient vehicle design iterations process. As an alternative approach to running simulations for long periods of time, the impact of adding artificial turbulence to the inlet on wake behavior and its potential impact on reduced runtime for design process is investigated in this study. By adding turbulence to the upstream flow, the wake
DeMeo, MichaelParenti, GuidoMartinez Navarro, AlejandroShock, RichardFougere, NicolasRazi, PooyanOliveira, DaniloLindsey, CraigYu, ChenxingBreglia Sales, Flavio
The difficulties of testing a bluff automotive body of sufficient scale to match the on-road vehicle Reynolds number in a closed wall wind tunnel has led to many approaches being taken to adjust the resulting data for the inherent interference effects. But it has been very difficult to experimentally analyze the effects that are occurring on and around the vehicle when these blockage interferences are taking place. The present study is an extension of earlier works by the author and similarly to those studies uses the computational fluid dynamics analysis of three bodies that generate large wakes to examine the interference phenomena in solid wall wind tunnels and the effects that they have on the pressures, and forces experienced by the vehicle model when it is in yawed conditions up to 20 degrees. This is accomplished by executing a series of CFD configurations with varying sized cross sections from 0.4% to 14% blockage enabling an approximation of free air conditions as a reference
Gleason, MarkRiegel, Eugen
Experimental studies of wind tunnel blockage for road vehicles have usually been conducted in model wind tunnels. Models have been made in a range of scales and tested in a working section of fixed size. More recently CFD studies of blockage have been undertaken, which allow a fixed vehicle size and the blockage is varied by changing the cross section of the flow domain. This has some inherent advantages. A very recent database of CFD derived drag and lift coefficients for different road vehicle shapes and simple bodies tested in a closed wall tunnel with a wide range of blockage ratios has become available and provides some additional insight into the blockage phenomenon. In this paper a process is developed to derive the parameters influencing wind tunnel blockage corrections from CFD data. These are shown to be reasonably effective for correcting the measured drag and lift coefficients at blockage ratios up to 10%.
Howell, JeffButcher, DanielGleason, Mark
Thermal management is a key challenge in the design and operation of lithium-ion batteries (LIBs), particularly in high-stress conditions that may lead to thermal runaway (TR). Immersion cooling technology provides a promising solution by offering uniform cooling across all battery cells, reducing the risk of hotspots and thermal gradients that can trigger TR. However, accurately modeling the thermal behavior of such systems, especially under the complex conditions of immersion cooling, presents significant challenges. This study introduces a comprehensive multiscale and Multiphysics modeling framework to analyze thermal runaway and its propagation (TRP) in battery systems cooled by immersion in dielectric fluids. The model integrates both 1D and 3D simulations, focusing on calibrating energy terms at the single-cell level using 3D Computational Fluid Dynamics (CFD). The calibration process includes a detailed analysis of cell chemistries, exothermic heat release, and thermal runaway
Negro, SergioTyagi, RamavtarKolaei, AmirPugsley, KyleAtluri, Prasad
This Paper will focus on simulating thermal runaway propagation within a battery cell and module. The thermal runaway model parameters are derived from accelerating rate calorimeter (ARC). The simulation involves a thermal runaway propagation model that converts the stored energy of the battery materials into thermal energy, thereby simulating the propagation of thermal runaway. The initiation of thermal runaway is modelled through a nail penetration event, represented by a heat profile in the nail region. The resulting temperature rise in this area triggers the short propagation model, leading to the spread of thermal runaway. For the single-cell simulation, the 1-equation thermal runaway model is used, focusing on the direct energy conversion and propagation within the cell. In contrast, the module simulation involves a more complex scenario. Here, an initial temperature rise near the nail region activates a short propagation model, which subsequently triggers the 4-equation thermal
Wakale, AnilMa, ShihuHu, Xiao
Interest in Battery-Driven Electric Vehicles (EVs) has significantly grown in recent years due to the decline of traditional Internal Combustion Engines (ICEs). However, malfunctions in Lithium-Ion Batteries (LIBs) can lead to catastrophic results such as Thermal Runaway (TR), posing serious safety concerns due to their high energy release and the emission of flammable gases. Understanding this phenomenon is essential for reducing risks and mitigating its effects. In this study, a digital twin of an Accelerated Rate Calorimeter (ARC) under a Heat-Wait-and-Seek (HWS) procedure is developed using a Computational Fluid Dynamics (CFD) framework. The CFD model simulates the heating of the cell during the HWS procedure, pressure build-up within the LIB, gas venting phenomena, and the exothermic processes within the LIB due to the degradation of internal components. The model is validated against experimental results for an NCA 18650 LIB under similar conditions, focusing on LIB temperature
Gil, AntonioMonsalve-Serrano, JavierMarco-Gimeno, JavierGuaraco-Figueira, Carlos
This study investigates the impact of various notch geometries on the outer surface of the rotor of an interior permanent magnet synchronous motor intended for traction applications, focusing on improving both its thermal and electromagnetic performances. Traditional motor cooling methods, such as water jackets or oil spray/impingement, typically target the stator and/or end windings, neglecting rotor cooling. As a result, the dissipation of the heat from the rotor is dependent on the heat transfer across the air gap surrounding the rotor, despite air’s poor thermal conductivity, which causes it to act as an insulator. Rotor notches are used to limit the higher order harmonics from air gap flux density which results in decreased torque ripple, cogging torque, noise, and vibration of the machine. While the effect of rotor notches on electromagnetic performance is analyzed, their impact on the thermal management of the motor, particularly the heat transfer coefficient in the air gap
Zajac, ArthurDe Silva, BuddhikaLee, SunMistry, JigarNasirizarandi, RezaJianu, OfeliaKar, Narayan
The drive unit, primarily consisting of an electric motor and a gearbox, needs to be cooled and lubricated for its long life and efficient performance. In an extreme drive cycle condition, the pickup tube to the pump may get exposed to air, leading to a substantial loss in line pressure and a drop in oil flow rate to the subsystems. An advanced Computational Fluid Dynamics (CFD) simulation can provide insights into the oil delivery system and help in improving the oil sump design, optimizing the position of the pickup tube to the pump and oil delivery lines. The current study employs a Volume of Fluid (VOF) based multiphase model implemented in a commercial CFD solver, Simerics-MP+. The drive unit lubrication system considered in the study consists of a gerotor pump, the entire oil delivery lines to the two subsystems and the drive unit casing. A multiphase simulation of the system with transient operation of the pump is computationally expensive. Therefore, a new methodology is
Joe, Erin SamSchlautman, JeffManne, Venkata Harish BabuSrinivasan, ChiranthPasunurthi, Shyam Sundar
This paper introduces a new approach for measuring changes in drag force across different vehicle configurations using an on-road testing technique. The method involves fixing the vehicle’s power across configurations and then measuring the resulting speed differences. A detailed formulation is provided on how these speed variations can be used to calculate the change in drag force for each configuration. The OBD II port is used to access and record additional data necessary for the calculations. The method is applied to both a passenger car and a commercial van to evaluate drag changes for different vehicle add-ons. A roof sign was installed at various positions along the roof of the vehicles to assess drag increases, while novel rear appendages were fitted to both vehicles to evaluate the resulting drag reductions. Detailed CFD simulations were performed on the road-tested configurations to compare the simulated drag changes with those measured on the road. Excellent agreement was
Connolly, Michael GerardIvankovic, AlojzO'Rourke, Malachy J.
The U.S. DRIVE Electrical and Electronics Technical Team has set a goal for 2025 to achieve a power density of 33 kW/L for electric vehicle (EV) motors [1]. The increase in motor power density is highly dependent on effective thermal management within the system, making active cooling techniques like oil-jet impingement essential for continued advancements. Due to the time and expense of physical experimentation, numerical simulations have become a preferred method for design testing and optimization. These simulations often simplify the motor-winding surface into a smooth cylinder, overlooking the actual corrugated surface due to windings, thus reducing computational resources and mesh complexity. However, the coil's corrugated surface affects flow turbulence and heat transfer rates. This study utilizes three-dimensional Computational Fluid Dynamics (CFD) simulations to investigate the impingement-cooling of an Automatic Transmission Fluid (ATF) jet on a corrugated surface that
Mutyal, Jayesh RameshHaghnegahdar, AhmadGurunadhan, MohanaKonangi, SantoshChamphekar, Omkar
Controlling the combustion phasing of a multi-fuel compression ignition engine in varying ambient conditions, such as low temperature and pressure, is a challenging problem. Traditionally, engine control is achieved by performing experiments on the engine and building calibration maps. As the number of operating conditions increase, this becomes an arduous task, and model-based controllers have been used to overcome this challenge. While high-fidelity models accurately describe the combustion characteristics of an engine, their complexity limits their direct use for controller development. In recent years, data-driven models have gained much attention due to the available computation power and ease of model development. The accuracy of the developed models, which, in turn, dictates the controller’s performance, depends on the dataset used for building them. Several actuators are required to achieve reliable combustion across different operating conditions, and obtaining extensive
Govind Raju, Sathya AswathSun, ZongxuanKim, KennethKweon, Chol-Bum
A multi-dimensional model of the spark ignition process for SI engines was developed as a user-defined function (UDF) integrated into the commercial engine simulation software CONVERGE CFD. The model presented in this paper simulates energy deposition from the ignition circuit into the fuel-air mixture inside the cylinder. The model is based on interaction and collision between electrons in the plasma arc and the gas molecules inside the cylinder using parameters from the ignition circuit and gas inside the cylinder. Full engine simulations using CONVERGE CFD with the developed ignition model including the ignition circuit model, arc propagation model, and energy deposition model were performed to evaluate the validity and performance of the model and to compare with the ignition model provided by CONVERGE CFD. A low turbulent port fuel injected single-cylinder CFR engine was used for comparison. Continuous multi-cycle RANS simulations showed cycle-to-cycle variations. The range of the
Kim, KyeongminHall, MatthewJoshi, SachinMatthews, Ron
This paper presents transient, complex, moving mesh, 3-D CFD analysis of an intebrake lubrication oil circuit for predicting flow performance. Intebrake is a mechanism for improving braking performance during over speeding conditions. The mechanism briefly opens the exhaust valve at the end of a compression stroke with a small valve lift and releases the compressed gases, thereby helping in quick application of the brake. There is no fueling during the process and hence, no combustion induced pressure rise which helps in quick application of the brake. During the intebrake operation, opening of the exhaust valve is achieved by using a complex lube oil circuit inside the exhaust rocker lever. The intebrake lube oil circuit consists of various spring-operated valves with micro-sized clearances, high oil pressure generation up to ~ 250 bar, 3-D movement of the mechanism components, and it is a transient operation. The 3-D movement consists of simultaneous rotational and translational
Tawar, Ranjit RamchandraPasunurthi, Shyam SundarBedekar, SanjeevRanganathan, Raj
Diesel combustion is a highly heterogeneous process in which the fuel must undergo several sub-processes after injection in order to release its heat through combustion. Prior to evaporation, computational fluid dynamic (CFD) simulations track the injected fuel mass using a Lagrangian frame of reference to determine the pathlines of the liquid fuel in the gaseous environment. However, after evaporation, when the fuel mass becomes part of the working fluid, it is no longer tracked in a Lagrangian reference frame as it undergoes its mixing and combustion processes. To gain deeper insights into the diesel combustion process, a methodology is proposed to track the evolution of fuel mass packets while in the gaseous state attaining a Lagrangian-esque description of the fuel’s evolution. This is achieved using the commercially available capabilities in Convergent Science’s CFD package, without requiring user-defined functions. The methodology is applied to a heavy-duty diesel engine and
Gohn, JamesKumar, MohitGainey, BrianLawler, Benjamin
In the automotive industry, it is essential to consider not only how well specialty materials perform and are formulated, but also how efficiently and economically they can be applied during manufacturing. This becomes especially important during the early stages of development to prevent issues when these materials are used in new designs by automotive suppliers or manufacturers. With the rapid growth of electric vehicles (EVs), new materials are being used more frequently, and these materials may not have been as thoroughly tested as those used in traditional internal combustion engine (ICE) vehicles. Therefore, it is crucial to ensure that these materials can be applied correctly and efficiently from the start. One way to speed up the development process is through Computational Fluid Dynamics (CFD) modeling. CFD helps predict how materials will behave when dispensed, which is essential for developing the right equipment and conditions for applying these materials. Working with
Kenney, J. AndyDelgado, RobertoHossain, ArifNg, Sze-SzeThomas, RyanChyasnavichyus, MariusTsang, Chi-WeiHwang, MargaretWu, LanceDietsche, LauraMcmichael, JonathanRaines, KevinNelson, Grant
The efficient operation of electric vehicles (EVs) heavily relies on the proper lubrication of the E-drive unit components, particularly the transmission gears and bearings. Improper oil supply can lead to mechanical failures, while excessive oil can increase power loss due to churning. This study focuses on utilizing Computational Fluid Dynamics (CFD) simulations to analyze the impact of drive speed, oil level, and temperature on gear churning loss in E-drive units. The research also investigates the influence of a baffle plate on power loss and oil splash characteristics. The simulations, conducted using the volume of fluid (VOF) method in Simerics-MP+, consistently illustrate a reduction in power loss with rising oil temperature and reveal decreased gear churning loss with a baffle plate, especially under high-speed conditions, highlighting its potential for enhancing energy efficiency in EVs. Additionally, post-processing analysis of oil splash patterns sheds light on the
Kumar, P. MadhanMotin, AbdulPandey, AshutoshGanamet, AlainMaiti, DipakGao, HaiyangRanganathan, Raj
Electrochemical model of a fuel cell involves several parameters which influence its polarization curve. For a numerical fuel cell model to match experimental polarization curve, it is critical to find the right values of these parameters. It is hard to find the values of all the parameters experimentally, and hence parameter calibration is required. A fully automated workflow for calibration of fuel cell model parameters in a three-dimensional Computational Fluid Dynamic (CFD) simulation is created. The CFD model captures detailed electrochemistry and water phase change. The CFD polarization curve is generated by sequentially running a series of simulations starting from low current densities to high current densities. Experimental polarization curve is used as the validation target. An objective function is defined as the L2 norm of the difference between the experimental and the CFD generated polarization curve measured at various current densities. For calibration, eight fuel cell
Champhekar, OmkarJanakiraman, ArunGondipalle, SreekanthAjotikar, NikhilZehr, Randall
Lithium-ion batteries (LIBs) are critical components in electric vehicles (EVs) and renewable energy systems. However, conventional cooling techniques for LIBs often struggle to efficiently dissipate heat during fast charging and discharging, potentially compromising performance and safety. This study investigates the thermal performance of immersion cooling applied to an Electric Vehicle (EV) battery module comprised of NCA-chemistry-based cylindrical 21700 format Lithium-ion cells. The effectiveness of immersion cooling in reducing maximum cell temperature, temperature gradient, cell-to-cell temperature differential, and pressure drop within the battery module is evaluated on a detailed 3D model of a 360-cell immersion-cooled battery module that was developed, incorporating a well-established heat generation model based on theoretical analysis and experimental data to simulate the thermal characteristics of the battery system. The effects of the different fluid properties are first
Garcia, AntonioMicó, CarlosMarco-Gimeno, JavierElkourchi, Imad
Variable Displacement Vane Pumps (VDVPs) are widely used in lubrication systems for engines, transmissions, and electric drive units. This study presents a Computational Fluid Dynamics (CFD) analysis of a rotational VDVP, coupled with an Oil Control Valve (OCV), to establish a feedback loop that regulates the eccentricity of the cam ring, and consequently, the pump’s outlet flow rate. In previous studies, Simerics-MP+ has been successfully utilized to model the VDVP without considering the OCV’s effect. The OCV consists of a solenoid valve coupled with a spring-loaded spool valve. Due to the absence of the actual valve geometry, the valve behavior in the CFD model is represented by a 2-D table that correlates the control chamber flow rate with both the supply and control pressures. The eccentricity of the cam ring is determined through an iterative process, balancing fluid torques from the vane chamber pressures and control chamber pressure, along with the spring torque. Simulation
Khatri, Rachit RajeshLiu, YuchanPasunurthi, Shyam SundarAhmed, RayhanStallmann, JohnYang, BoHuang, YuliSivaji, RangarajanScheffler, David
One of the most critical enablers of hydrogen internal combustion engines is achieving rapid injection and mixing of hydrogen into the combustion chamber. Optimal cap is actively being investigated to improve the injector performance without major hardware modifications. In this study, detailed computational fluid dynamics simulations using the Reynolds-averaged Navier-Stokes (RANS) turbulence model were undertaken to investigate the behavior of hydrogen jets with various cap designs mounted on a hollow-cone injector within a constant volume chamber. It was found that the implementation of a cap in general enhances mixture formation, leading to a higher proportion of lean mixture over time. Key parameters, such as the cap's inner volume and throat area ratio, directly influence the amount of hydrogen mass trapped within the cap. A smaller volume or larger throat area ratio results in less trapped hydrogen mass. Excessive enlargement of the cap's throat area can lead to a decrease in
Zaihi, AbdullahMoreno Cabezas, KevinLiu, XinleiBen Houidi, MoezWu, HaoAlRamadan, AbdullahCenker, EmreMohan, BalajiRoberts, WilliamIm, Hong
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