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01.04.2021

MTZ Project Reports: Optimization of the Engine Water Jacket from Concept to Production-ready Level

By using complex thermal management strategies, it is possible to make the heat distribution of the engine more accurate and dynamic, thus increasing efficiency. As part of the FVV project “Accurate Temperature Management” (FVV no. 1266) at the Otto von Guericke University (OVGU) Magdeburg and the University of Stuttgart, an engine’s water jacket was used as an example to investigate how cooling efficiency can be opti-mized by using simulations. Particular focus was placed on the modeling of 1-D simu-lations, which are more economical than 3-D ones.

In all areas of the automotive and engine industry, the topics of efficiency improvement and emission reduction, due to the challenges of climate change, are strongly focused. More efficient and predictive development environments help to optimize heat distribution. The goal of the research project, which was conducted at the Insti-tute of Mobile Systems (IMS) at the OVGU and the Institute of Automotive Engineering (IFS) at the University of Stuttgart, was therefore to improve 1-D modeling. This reduces the scope of complex 3-D calculations (Computational Fluid Dynamics, CFD) and costly metrological investigations in the development process.

A practice-oriented universal method was developed to create a 1-D water jacket model. The focus was on the discretization strategy of the 3-D geometry and the calculation of the heat transfer using Nusselt correlations. Basis and reference are 3-D CFD simulations of the water jacket. The quality of the results was verified by heat balance measurements at the full engine as well as optical PIV measurements in the water jacket. The methodology was successfully validated on a large engine. The investigation of two engines with different size ratios and flow characteristics of the water jacket has confirmed the general validity of the methodology. The quality of the results of the 1-D heat transfer calculation was less than 5 % deviation with respect to the total heat input.

Project profile

The FVV in the MTZ and ATZ magazine

Results from Industrial Collective Research are accessible to all interested parties and thus final reports of FVV research projects will be presented to the public at our conferences in spring and autumn. In order to further promote the transfer of knowledge and the expansion of the prime movers innovation network, we publish articles on individual projects with particularly interesting new insights in the world's leading specialist magazines for the engine and vehicle industries. MTZ / ATZ and FVV have been working together successfully in this field for many years.

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