Modeling and Simulation of Automotive AC Components (Condenser & Piston) with Experimental Validation 2020-28-0357

The present paper describes two case studies for verification of numerical results with experimental results. Case Study: 1, shows the prediction of natural frequencies of the condenser assembly via numerical method and experimental method under free-free condition. The experimental method has been carried using Impact Hammer Testing. To get the numerical results close to the experimental results, parametric study has been carried out by varying the tube's shell thickness. After freezing the parameters, verified the same methodology on similar model condenser. The comparison study is carried out on the modal frequencies of condenser assembly through experimental and numerical methods. The comparison results exhibit a good trend and correlation, thus helping to develop a procedure to consider the tube fin thickness 'first time right' at the simulation stage. Case Study: 2, investigate and analyze the stress distribution on piston under actual running condition. Pressure analysis and thermo-mechanical analysis is done. The parameter used for the analysis is operating gas pressure, temperature and material properties of piston. The analysis predicts the natural frequencies, von-Mises stresses and resultant displacement via numerical method. Then validates the same with Universal Testing Machine. The comparison study is then carried out with factor of safety on the model through experimental and numerical methods. The comparison results exhibit a good trend and correlation. Thereafter, established the proficiency to mitigates the development cycle time, proto making & proto testing costs on similar models.