where the heat goes? thermal analysis of internal...
TRANSCRIPT
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Where the Heat goes?Thermal Analysis of Internal Combustion Engines
Global Star User Conference
Marcus Ende, Carolus Gruenig, Carsten Skrobanek, Christian Schramm, René Paessler
Vienna, March 17-19, 2014
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2
Thermal Analysis of IC EnginesOverview
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Introduction
CAE Procedure
Gas-side heat transfer
Coolant-side heat transfer
Validation
Summary
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Thermal Analysis of IC EnginesIntroduction
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
1990 20151995 2000 2005 2010
Year of Construction
Sp
ec.
En
gin
e P
ow
er
[kW
/l]
Four Cylinder Engines
• Downsizing of engines:
→ Increase of specific engine power
output
→ Higher thermal loading
→ Optimized and very effective
cooling system is needed
• Shorter development cycles
→ Less project time
→ Robust & accurate CAE process
→ Target for CAE
→ Predictive results are required.
→ Calculated structural temperatures within +/- 5 K from reality.
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Thermal Analysis of IC EnginesCAE Procedure
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Averaging over working cycle
αgas(x,t)
Tgas(x,t)
dm/dtCoolant
CFD Coolant Flow Simulation with solid (CHT)
STAR-CCM+
αgas*(x)
Tgas*(x)
1D Gas Exchange Simulation
GT-Power
n, P
Twall*(x)
Some Iterations
α*(x)
Tref*(x)
Thermomechanical Analysis (FEM)
ABAQUS
CFD Combustion Simulation
ES-ICE + STAR-CD
pint(t)
Tint(t)
mFuel
λ
pexh(t)
Texh(t)
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5
Thermal Analysis of IC EnginesGas-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Averaging over working cycle
αgas(x,t)
Tgas(x,t)
CFD Combustion Simulation
ES-ICE + STAR-CDdm/dtCoolant
CFD Coolant Flow Simulation with solid (CHT)
STAR-CCM+
αgas*(x)
Tgas*(x)
1D Gas Exchange Simulation
GT-Power
n, P
Twall*(x)
Some Iterations
α*(x)
Tref*(x)
Thermomechanical Analysis (FEM)
ABAQUS
pint(t)
Tint(t)
mFuel
λ
pexh(t)
Texh(t)
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6
Thermal Analysis of IC EnginesGas-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
− Wall heat transfer has influence on
thermodynamics, emissions, wall film, etc.
− Thermal loads are an important input for FEA
Motivation
− CFD simulation of working cycle / gas-side
heat transfer
− Cycle-averaging of heat transfer coefficients
and local gas temperatures
− Mapping to CFD-CHT model
Simulation Approach
− Detailed analysis of thermal loading
− Thermal boundary conditions for FEA
− Pre-calculation of structural temperatures
Result
�Realistic calculation of thermal loads on
engine structure is essential
CFD results working-cycle heat transfer
Cycle Averaging
CFD-CHT-Model
TGas [K]
Min.
Max.
TGasHTC
Crank Angle
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Thermal Analysis of IC EnginesGas-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Sensitivity analysis of combustion system parameters (Diesel)
� Combustion system specification should be considered as good as possible
� In real-life project work, these information are often not yet available
+0.07mm-0.2mm
-2°KW
1.5mg+50K +500mbar
+10%
-0.07mm
+0.2mm
+2°KW-50K -500mbar +20%
-20
-10
0
10
20
∆∆ ∆∆Q
W [%
]
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-0.2mm
-2+0.2mm
+2
-100
-50
0
50
100
150
∆∆ ∆∆Q
W [%
]
8
Thermal Analysis of IC EnginesGas-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Sensitivity analysis of basic CFD model parameters
� Turbulence model and wall function have the biggest impact
� Selection of suitable submodels is required
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Thermal Analysis of IC EnginesGas-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
� Selection of a suitable turbulence model is mandatory
Sensitivity analysis of turbulence modelling
Turbulence model
∆∆ ∆∆Q
W [%
]
0.0 %
-100.0 %
100.0 %
50.0 %
-50.0 %
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10
Thermal Analysis of IC EnginesGas-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Sensitivity analysis of wall function
� Selection of suitable wall function model is mandatory
Experiment (Woschni)
Wall Function Model C
Wall Function Model B
Wall Function Model A
Standard Wall Function
CA[°deg] 360270 450
Wall
Heat
Tra
nsfe
r
Heat
Tra
nsfe
r R
ate
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Thermal Analysis of IC EnginesGas-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Cycle-averaged heat input boundary condition from working-cycle CFD
Boundary heat fluxlow high
Combustion chamber Exhaust ports
Complete 4 cyl. model
Liner
� 3d effects captured (e.g. non-symmetric heat flux distributions)
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12
Thermal Analysis of IC EnginesCoolant-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
dm/dtCoolant
α*(x)
Tref*(x)
Thermomechanical Analysis (FEM)
ABAQUS
CFD Coolant Flow Simulation with solid (CHT)
STAR-CCM+
Averaging over working cycle
αgas(x,t)
Tgas(x,t)
CFD Combustion Simulation
ES-ICE + STAR-CD
αgas*(x)
Tgas*(x)
1D Gas Exchange Simulation
GT-Power
n, P
Twall*(x)
Some Iterations
pint(t)
Tint(t)
mFuel
λ
pexh(t)
Texh(t)
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Thermal Analysis of IC EnginesConjugate Heat Transfer Model
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Polyhedral calculation grid with conformal interfaces
� Sufficient discretisation necessary (approx. 20 mil. cells for R4 engine model)
12 mm
3 mm
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Thermal Analysis of IC EnginesCoolant-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Coolant properties
• Chemical composition of cooling fluids affects
→ Convective heat transfer behaviour as well as
→ More important, phase change behaviour / boiling heat transfer performance
� Detailled boiling behaviour of coolant fluid should be known
• Differences of surface
temperatures up to 20
K are observed
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15
Thermal Analysis of IC EnginesCoolant-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Boiling modelling
• Available models
• Single-phase Rohsenow model
• To be parameterised / calibrated
• But:
• No transition / film boiling effects captured
• No boiling supression at higher velocities captured
• Multi-phase transition boiling model
• To be parameterised / calibrated
• But not intended on stationary calculations
• Developed IAV approach
• Transition boiling model equations implemented via field functions in single-phase simulation
• Boiling suppression considered
• Calibrated with measurement data
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Thermal Analysis of IC EnginesCoolant-side Heat Transfer
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
Heat transfer performance Cylinder-head temperatures
∆∆∆∆T approx. 20K
high
low
Tem
pera
ture
Effects of different Coolant Boiling Performances
� Accurate description of coolant boiling behaviour is necessary
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17
Thermal Analysis of IC EnginesValidation
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
� This represents a successful simulation, but not yet in target range of +/- 5K
� Satisfying predictive simulations are still challenging
Liner Side Injector Glowplug Intake - Exhaust Exhaust - Exhaust
Differences Simulation to Measurement
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Thermal Analysis of IC EnginesSummary
© IAV · 03/2014 · MEn · DP-E24 · cd-adapco Global User Conference · Vienna · Where the heat goes?
→ Not only computational power is decisive but accurate submodelling of ALL
physics.
Near-wall processes
Near-wall flame extincion
Stagnation flow
Thermal radiation, soot layers
Boiling onset / suppression
Transition / film boiling
Fluid properties
Surface conditions / depositions
Contact resistance Deformations / gaps
Material properties
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Contact
Marcus Ende
IAV GmbH
Kauffahrtei 25, 09120 ChemnitzTelefon +49 371 237-34386
www.iav.com