Cross-Flow Radiator Design Using CFD for FSAE Car Cooling System and Its Experimental Validation Using the GEMS Data Acquisition System 2022-01-0374

The cross flow design of a radiator and its heat transfer and temperature drop was simulated then validated by using a data acquisition system during both static and dynamic running conditions of a Formula SAE car. The data acquisition system simulated and validated the radiator's cross flow design and heat transfer, as well as the temperature drop, under static and dynamic conditions in a car. The optimal radiator design determines the engine's operating temperature and the desired temperature drop gain through proper design of the inner core, number of fins and tubes, and radiator material. The purpose of a properly designed radiator is to prevent the combustion engine from heating up above its operating temperature [1]. The radiator's design is based on the operating temperature of the CBR 600RR engine. The highest temperature recorded was around 105°C, and in the worst case scenario, it can reach 110°C. As a result, an 8-10°C temperature drop is required for proper operation at operating temperature. The resulting heat dissipated through the water jackets and aluminum tube routing.

The cooling temperature sensor (CTS), in conjunction with the data acquisition system, is used to record temperature during the static and dynamic conditions of the vehicle. Various models based on numeric and computational simulation were evaluated to determine the effect of changing the radiator's dimension and fin efficiency for different sizes of the radiator. Moreover, the relation between dimensionless numbers, such as the Colburn factor and friction factor, was correlated with numeric analysis. Furthermore, the different mass flow rates of water were used to analyze the relationship between the temperature drop, Reynolds number, and Nusselt number for the radiator's optimal design and size. The effect of changing the average temperature on the friction factor and the Colburn factor was also determined.