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Abstract – This charge air cooler is extensively used in diesel engine mostly for marine
applications. The main purpose of a charge air cooler is to cool the engine air, ensuring efficient
performance. The main objective of the charge air cooler is to increase the heat dissipation
capacity and to reduce the outlet temperature. In this paper, the charge air cooler was designed,
simulated and developed in MAHLE Behr India Private Limited, Pune. Based on the simulation
results it is observed that heat rejection and outlet temperature were matched with the
requirement and tested values. Copyright © 2017 Praise Worthy Prize S.r.l. - All rights reserved.
Keywords: Charge Air Cooler (CAC), Heat Dissipation, Outlet Temperature, Simulation
Copyright © 2017 Praise Worthy Prize S.r.l. - All rights reserved https://doi.org/10.15866/ireme.v11i6.13135
414
S. P. Gadewar, S. H. Gawande, S. A. Barhate
concluding remark is given in Section 8. temperature, it was necessary to perform thermal analysis
to determine the required heat dissipation capacity of
propose charge air cooler. Thermal analysis is a tool,
II. Problem Statement and Objective which is often used as a mean for the study of heat
As per industrial and literature survey, it is observed transfer through structures. Hence in this study thermal
that a lot of work is carried out on a charge air cooler, but analysis is performed to calculate heat rejection from a
very little amount of research work is reported for charge air cooler. Eq. (1) is used to determine the
different tank material of a charge air cooler and its required heat dissipation capacity. In Eq. (1) specific heat
performance. Finally, the scope of this paper is to design capacity of the air at 150°C used was 1.02 kJ/kg0C:
and develop a charge air cooler with the objective to
increase the heat dissipation capacity and to reduce outlet Q m CP T (1)
temperature. The solution achieves a major a design goal
of developing a charge air cooler with different tank
material. where:
Q – Heat Rejection (kW)
m – Mass flow rate (kg/hr)
III. Working Principle of Charge Cp – Specific heat capacity (kJ/kg°C)
Air Cooler ∆T – Temperature difference (°C)
In diesel engine, charge air cooler is positioned Q = (509/3600) × 1.02 × (150 - 53) = 13.9 kW
between the turbocharger and the engine. Turbocharger
is a device which delivers a grander supply of Hence, the required heat dissipation capacity of charge
combustion air by compression. The hot air coming out air cooler under consideration was calculated to be
of the engine is passed through the turbocharger for 13.9kW. As per the requirement to accomplish the
compression. Increase in the density of the combustion objective it was necessary design charge air cooler as
air will increase combustion efficiency. Thus, the shown in Fig. 2. The charge air cooler was design as per
compressed air is passed through the charge air cooler to Behr standards. Table I shows major dimensional
increase density of the air which indirectly lowers the parameters of designed charge air cooler. In this section
temperature of the air. This cooled air, then further complete design of charge air cooler and solid modeling
supplied to engine. Also, increase in density of the performed by using CATIA V5 software is presented.
cooling air will lead to an increase in weight of the The charge air cooler contains parts like Header, Inlet
charge air of the system, which in turn leads to an Tank, Outlet Tank, Side Plate, Tube and Fin. Charge air
increase in engine efficiency. The schematic layout of cooler was designed by considering some factors like
experimental test set-up developed at MAHLE Behr cost, weight and the performance. In design more
India Private Limited, Pune for measurement of outlet emphasis has given to the simplicity, rigidity and the
temperature of charge air cooler was as shown in Fig. 1. outer appearance.
The experimental setup consists of temperature
sensors (TS) to sense the temperature and pass the signal
further for processing. The experimental work was
carried out to measure the outlet temperature with the
help of the temperature sensors (TS).
TABLE I
Fig. 1. Test set-up for outlet temperature measurement DIMENSIONS OF CHARGE AIR COOLER
Parameters Dimensions
Core Size 277×259×40
IV. Thermal Analysis Fin Density – External 65 fpdm
In order to accomplish the objective as, to increase the Fin Density – Internal 65 fpdm
Number of tubes 18
heat dissipation capacity and to reduce the outlet Tube Pitch 15 mm
Copyright © 2017 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 11, N. 6
Special Issue on “ICMESCoE-2017”
415
S. P. Gadewar, S. H. Gawande, S. A. Barhate
TABLE II
MATERIAL PROPERTIES
Material Polypropylene Glass
Aluminum
fiber (PP66 GF30)
Header, Tubes, Inlet and Outlet Tank
Parts
Core Plate, Fin
Young’s Modulus E 63000-67000 6000-15000
(MPa)
Poisson’s Ratio ν 0.33 0.38 Fig. 6. Core Plate
Mass Density ρ 2.7 1.36
(ton/mm3) TABLE IV
Thermal Expansion 2.4 5.25 DIMENSION OF CORE PLATE
Co. α (mm/K) Parameters Dimension
Core Plate width 40 mm
Length of core plate 280 mm
IV.2. Design of Inlet and Outlet Tank Thickness of core plate 1.5 mm
Fig. 7. Tube
Copyright © 2017 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 11, N. 6
Special Issue on “ICMESCoE-2017”
416
S. P. Gadewar, S. H. Gawande, S. A. Barhate
Copyright © 2017 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 11, N. 6
Special Issue on “ICMESCoE-2017”
417
S. P. Gadewar, S. H. Gawande, S. A. Barhate
From Fig. 11 it is seen that the values of outlet Prediction and Validation of a Cross-Flow Wet Cooling Tower,
International Journal on Heat and Mass Transfer - Theory and
temperature obtained by two approaches are in good
Applications, Vol.4, n.3, pp.66-71, 2016.
agreement as the percentage deviation of outlet
temperature with the cooling air speed is negligible i.e.
varying from 20C to 3.60C. Authors’ information
1,2
Department of Mechanical Engineering, M. E. Society’s College of
Engineering, Pune, Maharashtra, India
VII. Conclusion E-mail: spgadewar@mescoepune.org
shgawande@yahoo.co.in
The primary objective of this paper was to design and
develop a charge air cooler with the objective to increase S. P. Gadewar is working as Assistant
the heat dissipation capacity and to reduce the outlet Professor at M.E.S. College of Engineering,
temperature. This objective was achieved with the help Pune, India. He obtained B.E. (Mechanical
of extensive analytical work, computer aided simulation Engg.) from SRTM University in 1999. LLB.
from 2006 SRTM University. M.E.
tools, commercially available software’s, and (Mechanical-Mfg.Processes) in 2010 from
experimental investigations. The design of the charge air SRTM University. His research areas are
cooler was carried out using company standards both Material science and welding technology. He
manually and by using software. Finally it is concluded has more than 11 years of teaching experience in various subjects of
Mechanical Engineering.
that results of heat rejection obtained by three approaches
are in good agreement as the percentage of deviation of Dr. S. H. Gawande was born in small village
heat rejection with the cooling air speed is very minute. Deori, Tq. Akot, Dist. Akola in Maharashtra
Again the values of outlet temperature obtained by three state of India. He completed bachelors degree in
mechanical engineering from Amravati
approaches are in good agreement as the percentage of University, Amravati in May 2001 & masters
deviation of outlet temperature is negligible. Lastly it can degree in Mechanical Engineering with design
be concluded that the solution achieves a major design engineering as specialization in December 2002
goal of developing a charge air cooler with different tank from University of Pune. He completed PhD in
Mechanical Engineering from Government College of Engineering,
material. Pune, (COEP) under University of Pune in September 2012. Now he is
working as professor in mechanical engineering at M. E. Society’s
College of Engineering Pune-411001, India from 2004. He published
Acknowledgements more than 50 research papers in international journals and conferences.
He is recognized PhD guide in mechanical engineering of Pune
The authors wish to thank MAHLE Behr India Private University, Under his guidance 5 PhD scholars are working. He has
Limited, Pune for giving me an opportunity to work in more than 14 years of teaching and industrial experience. His area of
interest is internal combustion engines, design engineering, tribology
this field. and vibration control. He is permanent member of Indian society ISTE
from 2005, IACSIT Singapore from 2009,ACSE and SAE from 2008.
Copyright © 2017 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 11, N. 6
Special Issue on “ICMESCoE-2017”
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