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Automotive

FEXILON has a dynamic presence in the CFD simulations of Automotive systems right from wind-shield analysis, spoiler-design, manifold design etc. Our team has accomplished the Underhood Thermal Management of an upcoming Sedan for a Japanese Auto-major, in record-time.

Fexilon offers the following CFD solutions for its Automotive clients:

  • External Aerodynamics
  • On-road & Off-road vehicles
  • Windshield design
  • Under Hood Thermal Management (UHTM)
  • HVAC – Cabin comfort
  • IC Engine simulation
  • Drag estimation
  • Coolant systems design
  • Combustion simulations
  • Lubrication design
  • Fuel system simulations
  • Intake & exhaust manifolds
  • Filters optimization
  • Combustion, sprays, surface chemistry
  • Pump design
and more ...





Thermal Analysis of Diesel-engine Manifold

Summary

This analysis was performed to study the temperature distribution across the solid as well as the fluid component of an automotive engine-manifold. The manifold geometry was wrapped using CCM+ and meshed with polyhedral mesh. The Conjugate Heat Transfer – CHT analysis was run to map the thermal field. The study of temperature variation across the walls of the manifold was used while estimating the thermal stresses.
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Radiator Fins Cooling

Summary

The purpose of this project is to check the capabilities of a car-radiator for multiple configurations. 3D model of the radiator is used to simulate the fluid-flow through the water-cooled radiator. The trimmer-mesh with prism-layers are used to capture the thermal-gradients accurately.
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Optimization of Radiator Fins

Summary

This project aimed at optimizing the radiator-design, by identifying the most effective geometry and configuration of the fins. The effect of the parameters namely shape, size and spacing of the fins on the radiator efficiency was analyzed. Design of Experiments – DOE was conducted by analysing various CFD models of the radiator to arrive the optimal design of the radiator-fin.
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Under Hood Optimization for Passenger-car

Problem Statement

  • To study the flow-thermal interactions in the Under-Hood cabin of a passenger-car
  • To improve the engine-room cooling performance.

Key Challenges

  • Large Assemblies (Engine, powertrain, radiator, fan, pumps etc.)
  • Complex physics with: Moving parts & Multi-phase flows

Accomplishments

  • Moving parts simulated
  • Transient Conditions included
  • Flow and Thermal conditions optimized through UHTM
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Climate control & Cabin ventilation

Problem Statement

  • Cabin-comfort study of an automotive.

Solution

  • Established the thermal field in the passenger cabin of a car.
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IC Engine Port Flow

Problem Statement

  • Flow study in an IC engine port

Key Challenges

  • CFD model developed using Star-CCM+
  • Moving-mesh defined to control valve displacements
  • Established the flow-field in the port of an IC engine

Accomplishments

  • Moving parts simulated
  • Transient Conditions included
  • Flow and Thermal conditions optimized through UHTM
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External Aerodynamics

Scope

  • Establish Aerodynamic Drag and Lift around the car

Methodology

  • Structured Mesh generated using HEXA cells
  • Appropriate Boundary Layers used
  • Thermal & Flow BCs applied
  • Model validated through mesh-sensitivity study

Solution

  • Established the flow-field around the vehicle
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