Heat exchangers are integral parts for thermal management and find countless applications in automotive, aerospace, energy, nuclear power plants, HVAC, etc. Due to intensive research & development and technological advancements in manufacturing technologies, there is an increasing rise in demand for high-performance heat exchangers. In the automotive and aerospace industries, heat exchangers are expected to deliver better thermal efficiency and improve the system’s overall functionality in which they are installed by saving space and being lightweight. Additive Manufacturing (AM) is a ground-breaking and promising technology that offers avenues of opportunities to manufacture parts that were almost impossible to be produced with conventional manufacturing and can improve part performance with lightweight and compact designs. Laser-Based Powder Bed Fusion (LPBF), one of the well-known AM techniques, provides freedom to design complex geometries and fabricate them in a layer-by-layer fashion by exposing a high-density laser on a vertically moving powder bed. The study focuses on the application of AM in re-designing heat exchangers under given design requirements using LPBF. It includes exploring Triply Periodic Minimal Surfaces (TPMS) based structures such as gyroid and realizing them as heat exchanger core. Computational gyroid-based heat exchanger core models were designed and analyzed for thermal and fluid dynamics characteristics. A parametric study and analysis based on gyroid TPMS network type, periodic length, thickness, aspect ratio, and functional grading were carried out to optimize heat exchanger performance as per design conditions and validate their manufacturability using LPBF. Successful printable designs were further used to develop and manufacture prototypes. The study concludes with a comparison between additively manufactured gyroid-based design and conventional shell-and-tube design based on the thermal performance from CFD analysis and the weight of prototypes. It was found that the thermal performance from CFD analysis showed an 18.96% improvement, whereas weight was reduced by 14.8% for the gyroid-based design as compared to the conventional shell-and-tube design. / Thesis / Master of Applied Science (MASc)

Denna rapport ingår i ett examensarbete på avancerad nivå inom ämnet produktutveckling.Arbetet innefattar en fallstudie som genomförts vid RTGA, Scania CV AB i Södertälje.Examensarbetet omfattar 30 högskolepoäng och har genomförts av undertecknad,teknologstudent från Mälardalens Högskola vårterminen 2015. Rapporten har upprättats i tvåversioner, en för Scania CV AB respektive en generell version där känslig företagsspecifikinformation har censurerats. I takt med att utvecklingen av motorprestanda fortskrider, med avseende på ökademotoreffekter samt teknikutveckling för emissionsreglering, så ökar också kravet på prestandaför kylsystem som måste klara av att kyla bort högre effekter. Fordonskombinationer medkraftfulla laddluftkylare löper dock stor risk att drabbas av utfälld kondens som fryser till is iladdluftkylaren vid låga omgivningstemperaturer. Isen medför ett tryckfall i laddluftkylarenmed prestandabortfall som följd. Scanias lösning till problematiken är en så kallad kylargardinsom syftar till att reducera kylluftflödet genom laddluftkylaren till den mån att isbildning intesker. Kylargardinen monteras manuellt av föraren framför kylarpaketet dåomgivningstemperaturen understiger 5 °C. Det finns även andra fördelar med att begränsa det yttre kylluftflödet som passerar genomkylarpaketet. Lastbilars kylsystem är i regel överdimensionerade för normala driftfall såsommotorvägskörning vilket betyder att maximal kylning inte krävs vid dessa situationer. Genomatt reducera det yttre kylluftflödet genom kylarpaketet så kan även hela fordonets totalaluftmotstånd reduceras vilket kan utnyttjas i syfte att reducera bränsleförbrukningen. För att erhålla en bra balansgång mellan aerodynamik och kylprestanda samt motverkaproblemet med isbildning i laddluftkylaren fanns därför en önskan om att en reglerbarkylartäckning skulle utvecklas för att kunna reglera kylluftflödet genom fordonets kylarpaketvid behov. Detta arbete innefattar en fallstudie där olika produktutvecklingsverktyg använts för att ta framolika konceptlösningar, anpassade för en specifik lastbil. Datorstödda flödessimuleringarutnyttjas för att utvärdera respektive verifiera konceptens funktion jämfört med olika referensmodeller. Resultatet visar bland annat att det slutgiltiga konceptets funktionsduglighet överensstämmermed den lösning som används idag samt att kylluftflödet inte påverkas nämnvärt då maximalkylkapacitet eftersträvas. Resultatet från den aerodynamiska flödessimuleringen indikerar ävenatt fordonets totala luftmotstånd kan reduceras med - Drag Counts (DC) vid hastigheten90 km/h och 0° vindriktning. Detta medför att bränsleförbrukningen i det specifika driftfallet,enligt tumregel, antas reduceras med - % för det specifika fordonet. / This report is part of a Master thesis project in the subject of Product Development. The workincludes a case study which was carried out at RTGA, Scania CV AB in Södertälje. The workcomprises 30 credits and was conducted by a student from Mälardalen University during thespring semester 2015. The report has been prepared in two versions; one for Scania CV AB anda generalized version where sensitive company specific information has been censored. The development of vehicle engine performance progresses in a rapid pace. This progressinclude increased engine power and improved technical features for emission control. This alsogoes for the requirement on performance of cooling systems in heavy trucks, which has tohandle dissipation of the increased power. Vehicles with powerful charge air coolers however,runs a high risk of being affected by iced condensation in the charge air cooler at low ambienttemperatures. The ice build-up results in a pressure drop in the charge air cooler with a loss ofengine performance as a consequence. Scania's solution to the problem is a so called radiatorblind designed to reduce the cooling air flow through the charge air cooler to the extent thatice build-up does not occur. The blind is mounted manually in front of the cooler package whenthe ambient temperature is expected to be below 5 °C. There are also other advantages to limit the outer cooling air flow passing through the coolingpackage. The cooling systems in heavy trucks are usually oversized for normal operatingconditions such as highway cruising, which means that maximum cooling is not required inthese situations. By reducing the airflow through the cooler package, the vehicle's total airresistance is reduced, which can be utilized in order to reduce fuel consumption. To obtain a good balance between aerodynamics and cooling performance, and to counteractthe problem of ice build-up in the charge air cooler, there was a desire for an adjustable radiatorcoverage which would be able to regulate the airflow through the vehicle's cooling packagewhen needed. This work includes a case study in which various product development tools are used toinvestigate different concept solutions, designated for a specific truck model. Computationalfluid dynamics (CFD) are used to evaluate and validate the concept’s functionality andcomparing them to different reference models. The results reveal that the final concept functionality is consistent with the one used today, andthat the cooling air flow is not significantly affected when maximum cooling capacity is strivedfor. The results of the aerodynamic flow simulation also indicate that the vehicle's total airresistance can be reduced by - Drag Counts (DC) at the speed of 90 km/h and 0° yaw angle.This means that fuel consumption in the specific operating case, as rule of thumb, is assumedto be reduced by - % for the specific vehicle.

Economical and environmental factors together with energy policies towards more efficient systemsare the driving force for the development of the vehicle industry. Significant changes have beenmade to fulfill new emissions legislation but the basic internal combustion vehicle architecture hasbeen kept. New emission treatment systems that increase the thermal loading of the cooling systemhad been added within the same package envelope as before, which means less space to place coolingfans and a greater need for airflow. Changes in the cooling system, namely the replacement of thehydraulic fan drive system by electrical fans is one of the energy efficient alternatives for severalcity buses under certain environments, like the ”typical red city buses”, well-known in the UnitedKingdom. In this thesis study, hydraulic fans are compared with electrical fans and a road-mapof the benefits and drawbacks of the two systems is developed, based on real traffic performanceperformance data and the results of existing simulations and tests. In addition, new simulations arepresented in order to find the most efficient design for the cooling system as well as a comparisonof these results with previous ones. This road map will be used later by Volvo-Buses Group as atool to better understand in which circumstances electrical fans can be beneficial, in terms of fuelconsumption, noise production, cooling performance, control of the fans and associated costs.

Shorter product development cycles, densely packed engine compartments and intensified noiselegislation increase the need for accurate predictions of IC-engine air intake noise at earlystages. The urgent focus on the increasing CO2 emissions and the efficiency of IC-engines, aswell as new techniques such as homogeneous charge compression ignition (HCCI) mightworsen the noise situation. Nonlinear one-dimensional (1D) gas dynamics time-domainsimulation software packages are used within the automotive industry to predict intake andexhaust orifice noise. The inherent limitation of 1D plane wave propagation, however, limitsthis technique to sufficiently low frequencies where non-plane wave effects are small. Thereforethis type of method will first fail in large components such as air cleaners. Further limitations,that might not be important for simulation of engine performance but indeed for acoustics,include difficulties to apply frequency dependent boundary conditions and losses as well as toinclude effects of vibrating walls. The first part of this thesis treats two different strategies to combine nonlinear and linearmodelling of intake systems in order to improve the accuracy of the noise predictions. Paper Adescribes how a linear time-invariant one-port source model can be extracted using nonlineargas dynamics simulations. Predicted source data for a six-cylinder naturally aspirated engine isvalidated using experimental data obtained from engine test bench measurements. Paper Bpresents an experimental investigation on the influence of mean flow and filter paper on theacoustics of air intake systems. It also suggests how a linear source, extracted from nonlinearsimulations can be coupled to acoustic finite elements describing the intake system and toboundary elements describing the radiation to the surroundings. Simulations and measurementsare carried out for a large number of engine revolution speeds in order to make the firstsystematic validation of an entirely virtual intake noise model that includes 3D effects for awide engine speed range. In Paper C an initial study on a new technique for the use of two-portsin the time domain for automotive gas dynamics applications is presented. Tabulated frequencydomaintwo-port data representing an air cleaner unit on the impedance form is inverselytransformed to the time domain and used as FIR filters in nonlinear time-domain calculations. The second part of the thesis considers detailed modelling of sound propagation in capillarytubes. Thermoviscous boundary effects and interaction between sound waves and turbulencecan, for sufficiently narrow tubes, yield significant attenuation. Several components in the gasexchange system of IC-engines are based on arrays of narrow ducts and might haveunderestimated silencing capabilities. In particular the sound transmission properties of chargeair coolers (CAC) have so far gained interest from very few authors. In Paper D a detailedinvestigation of the acoustic properties of CACs is presented. As a result the first linearfrequency-domain model for CACs, which includes a complete treatment of losses in the narrowtubes and 3D effects in the connecting tanks, is proposed. Interesting low frequency dampingmost likely due to interaction between sound and turbulence is observed in the experimentaldata. A new numerical model that describes this dissipative effect in narrow tubes is suggestedin Paper E. Validation is carried out using experimental data from the literature. Finally, inPaper F the CAC-model presented in Paper D is updated with the new model for interactionbetween turbulence and acoustic waves proposed in Paper E. The updated model is shown toyield improved predictions. / QC 20100723

A masters thesis deals with the question of deisel engine boosting by rotary turbochargers. The objective of the thesis is to propose suitable turbocharger´s concept for defined diesel combustion engine with power of 430 [kW]. The air boosting pressure is controlled by exhaust gas flow through the turbine and different EGR regimes, which are considered in the basic and corrected calculations. The final turbocharger´s concept is proposed to satisfy the defined technical requirements. Next technical recommendations are briefly summarized in the thesis conclusion for following turbocharger´s concept application.