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A CFD Study of Water Condensation Inside the Tubes of an Automotive Compact Charge Air Cooler Using Large Eddy Simulation Approach

[+] Author Affiliations
Robin Cash, Bashar AbdulNour

Ford Motor Company, Dearborn, MI

Apoorv Talekar

Wayne State University, Detroit, MI

Paper No. IMECE2016-66999, pp. V008T10A068; 6 pages
  • ASME 2016 International Mechanical Engineering Congress and Exposition
  • Volume 8: Heat Transfer and Thermal Engineering
  • Phoenix, Arizona, USA, November 11–17, 2016
  • Conference Sponsors: ASME
  • ISBN: 978-0-7918-5062-6
  • Copyright © 2016 by ASME


The usage of compressed air generated by supercharger or turbocharger by automotive Original Equipment Manufacturers (OEM) is growing with the aim to increase engine performance by increasing the density of the air charge being drawn into the cylinder. Denser air coupled with more fuel pulled into the combustion chamber results in increased engine performance. The inlet air is heated during compression which can cause pre-ignition, which leads to reduced engine functionality. The charge air cooler (CAC) is a heat exchanger introduced to extract heat created during the compression process. Previous research developed a 3-D Computational Fluid Dynamics (CFD) model using the k-epsilon turbulent model with near wall treatment to resolve turbulence in the small channels of the CAC. [1] The present research uses a refined computational scheme with a Large Eddy Simulation (LES) model to solve local data as a function of time and location and correlates the result to the experimental measurements, as well as compare to the k-epsilon approach. Using LES resulted in the ability to correlate any portion of the experimental data and take a closer look at local heat transfer between the outside surface of the tube and the cooling air. Large Eddy Simulation for heat transfer gave more information required for design of CACs which is difficult to collect for various operating conditions by experiment. The overall benefit presented is a validated simulation methodology that predicts condensation, which is then used to evaluate and design CACs that function outside the condensate formation zone during various vehicle operation modes.

Copyright © 2016 by ASME



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