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This paper presents the benefits of following a disciplined thermal management process during the design and development of Ford Light Truck engine cooling systems. The thermal management process described has evolved through the increased use of Computer Aided Engineering (CAE) tools. The primary CAE tool used is a numerical simulation technique within the field of Computational Fluid Dynamics (CFD). The paper discusses the need to establish a heat management team, develop a heat management model, construct a three dimensional CFD model to simulate the thermal environment of the engine cooling system, and presents CFD modeling examples of Ford Light Trucks with engine driven cooling fans.

This paper presents the benefits of following a disciplined thermal management process during the design and development of Ford Light Truck engine cooling systems. The thermal management process described has evolved through the increased use of Computer Aided Engineering (CAE) tools. The primary CAE tool used is a numerical simulation technique within the field of Computational Fluid Dynamics (CFD). The paper discusses the need to establish a heat management team, develop a heat management model, construct a three dimensional CFD model to simulate the thermal environment of the engine cooling system, and presents CFD modeling examples of Ford Light Trucks with engine driven cooling fans.

The paper presents the design, development, heat transfer performance and durability characteristics of a new Mechanically Assembled Aluminum Radiator (MAAR) with elliptical shaped tubes for coolant passages. This unique ET-MAAR represents significant product improvements in performance, weight and cost, when compared to a conventional round tube mechanically assembled aluminum radiator. The use of computer modeling techniques to assist in design optimization, and the development of a finite element model to analyze a unique tube-to-fin expansion joint is also discussed.

This paper discusses the design, development and manufacturing of the Ford mechanically assembled aluminum radiator. This new product is lighter in weight, lower in cost, and has superior reliability and durability compared to its copper and brass counterpart. Extensive research and development by Ford of coolants, corrosion inhibitors, and the use of an air side sealant at the tube to header interface has made the mechanically assembled aluminum radiator very attractive for vehicle applications where moderate cooling requirements exist.