Coupling 1-D/CFD/FEA tools in a transient thermal stress analysis with non-uniform air flow distribution

摘要

This paper describes the methodology used to conduct a transient thermal stress analysis on a radiator core by coupling 1-D/CFD/FEA tools in a non-uniform external air flow distribution. Non-uniform external air flows are typically found in underhood, vehicular front-end cooling modules. As part of the study, experimental test data for the heat-exchangers in the module was regressed into non-dimensional equations which describe the thermal characteristics of the fluids. Underhood CFD analysis was completed to determine the velocity distribution over the cooling module, including air flow maps of the charge air cooler and radiator, and then was linked with 1-D models to generate heat transfer coefficients to be used as boundary conditions for the FEA thermal stress analysis. The effects of non-uniform air flow distribution on the thermal stresses of the radiator were reviewed. By completing this study, a methodology was developed to link ID, CFD, and FEA tools together. This methodology was converted into an automated computer process, increasing efficiency which allows the technique to be more readily adopted into the product development process.