Design Selection and Numerical Simulation Analysis of Diesel Engine Intercoolers

DOI: https://doi.org/10.62517/jiem.202503413

Author(s)

Wang Xuyan

Affiliation(s)

School of Energy and Power Engineering, North China University of Technology, Taiyuan, Shanxi, China

Abstract

Addressing the coupled trade-off between heat transfer efficiency and flow resistance in heavy-duty diesel engine intercoolers, this study focuses on engines meeting China VI emission regulations. Employing a progressive design approach—"structure selection, layout optimization, simulation validation"—research was conducted using Converge for detailed numerical simulation. First, the comprehensive performance of two intercooler configurations—Type A (coolant inside tubes, gas outside tubes) and Type B (gas inside tubes, coolant outside tubes)—was compared. Based on thermal performance (higher turbulent heat transfer coefficient for Type B) and engineering adaptability (flexible layout, easy maintenance), Type B was selected as the baseline design. Subsequently, a 3D model was established using SolidWorks. Numerical simulations employing the RNG k-ε turbulence model and conjugate heat transfer (CHT) model validated the independence of the 1.8 million mesh density. Simulation results indicate that the core section temperature drop reaches 91K, approaching the target of 90℃. However, heat accumulation occurs in the inlet section, with low-speed vortex zones present in the intake chamber and curved outlet piping sections, accompanied by uneven internal airflow distribution. Finally, improvement measures such as optimizing the inlet guide structure and adjusting the heat exchange tube layout are proposed to enhance heat transfer efficiency and flow uniformity, reduce friction loss, and meet the energy-saving and consumption-reduction requirements of diesel engines.

Keywords

Diesel Engine Intercooler; Structural Selection; Numerical Simulation; Heat Transfer Characteristics; Flow Resistance

References

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