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Durability assessments of modern engines often require accurate modeling of thermal stresses in critical regions such as cylinder head firedecks under severe cyclic thermal loading conditions. A new methodology has been developed and experimentally validated in which transient temperature distributions on cylinder head, crankcase and other components are determined using a Conjugate Heat Transfer (CHT) CFD model and a thermal finite element analysis solution. In the first stage, cycle-averaged gas side boundary conditions are calculated from heat transfer modeling in a transient in-cylinder simulation. In the second stage, a steady-state CHT-CFD analysis of the full engine block is performed. Volume temperatures and surface heat transfer data are subsequently transferred to a thermal finite element model and steady state solutions are obtained which are validated against CFD and experimental results.

Truck underhood thermal management has become a critical design parameter to meet the increasingly stringent U.S. federal EPA (Environmental Protection Agency) diesel emissions standards. Both heat exchanger modules and vehicle design details have significant impact on the cooling performance. This paper introduces an integrated numerical modeling approach utilizing one way coupled solution combining 3-dimensional finite volume computational fluid dynamics (CFD) method and 1-dimensional simplified system model to simulate full complicated airflow and heat transfer activities. The results are validated against experimental data based on some selected actual vehicle operating conditions for two designs configurations including a new and improved cooling module design.