The Structural Design And Heat Transfer And Flow Resistance Of Vehicle Intercooler Characteristic Analysis

The intercooler is one of the most important components of the turbocharged technology and is widely used in many fields,especially in the automotive industry.The structural design and layout of the intercooler are critical to the maneuverability of the vehicle,so it is necessary and meaningful to carry out the relevant research.In this paper,the intercooler of a luxury passenger car was taken as the research object.According to the available space of the engine compartment,the theoretical enhanced heat transfer study and structural design of the plate-fin intercooler were carried out.The structure size of the body is 500 mm × 124.8mm × 64 mm,and the heat transfer rate is 8.088 kW,which accords with the heat transfer requirement.The pressure drop of the hot side and the cold side is 4023 Pa and 2002 Pa,respectively,which are lower than the limit pressure drop of intercoolers.The three-dimensional model of the plate-fin type intercooler was created by SolidWorks,and the model was simulated and analyzed by a CFD software.The distribution of the temperature field,pressure field and velocity field was obtained.From the results of the simulation,it can be found that the temperature of the cross section of the hot side of the intercooler shows the distribution of the “The middle temperature is high and the surrounding temperature is low ".The pressure gradient and velocity gradient near the inlet and outlet of the hot side are large,and accompanied by the generation of eddy currents.Comparing the simulation results with the experimental results,the results show that the hot side inlet and outlet temperature difference 4.1%,the hot side inlet and outlet pressure drop difference10.8%.This error is acceptable in the engineering calculation range.Therefore,the numerical simulation results have reference significance.In addition,the heat transfer of the single heat exchanger unit of the intercooler was studied.The influence of fin spacing,fin height and cold side mass flow rate on the heat transfer performance of the plate-fin type intercooler was analyzed.It was found that when the fin spacing increased from 4mm to 8mm,the heat transfer rate increased from 1422 W to 1571 W,and the heat pressure drop gradually decreased.When the fin height increases from 6mm to 14 mm,the heat transfer rate increases from 1503 W to the maximum value of 1643 W and then decreases to 1609 W,the pressure drop from 470 Pa gradually decreased to 103 Pa.There is an almost linear relationship between the cooling side air flow and the heat transfer.The larger the mass flow rate is,the greater the heat transfer is and the pressure drop on the hot side remains basically unchanged.