Car Radiator Design Calculations

VI.
DESIGN CALCULATIONS
This part discusses and presents data calculations on the analysis of heat transfer
within an automobile radiator heat exchanger.
It is critical to state the assumptions prior to presenting the theoretical computations.
The assumptions are as follows:
✓ In this model of heat transfer of a car radiator we can assumed a progression
of convection to conduction to convection again, modeling with one-
dimensional steady heat flow. The convection of the coolant through the
conduction of cylinder walls of tubes and fins to the convection of the air flowing
the core of the radiator.
✓ The automobile radiator is at steady state and a cross-flow heat exchanger.
✓ The specific heat of each stream remains constant throughout the exchanger.
✓ All elements of a given fluid stream experience the same thermal history as
they pass through the heat exchanger.
✓ The velocity and temperature of each stream fluids at the inlet and outlet are
constant throughout the heat exchanger.
Radiator Model Dimensions

The table below summarizes the designed radiator dimensions.
Name Dimension in SI Unit
Radiator Length 0.6 m
Radiator Width 0.4 m
Radiator Height 0.025 m
Tube Height 0.025 m
Tube Width 0.0015 m
Fin Height 0.014 m
Fin Width 0.025 m
Distance Between Fins 0.0015 m
Number of Tubes 28 tubes
Fin Thickness 0.0005 m
Tube Thickness 0.000025 m

VI. DESIGN CALCULATIONS
Radiator Operating Conditions

The table below summarizes the designed radiator operating conditions.
Name Operating Conditions
Coolant Volumetric Flow 0.0018927 m3/s
Air Volumetric Flow 1.10860 m3/s
Air Velocity (Fan) 4.47 m/s
Aluminum Thermal Conductivity (Tubes) 237 W/m-K
Carbon Foam (Graphite) Thermal Conductivity

180 W/m-K
(Cooling Fins)
Coolant Property Table (Glycol-Water)

The thermal fluid properties for the coolant is listed in the following.
Name of the Properties Properties Equivalent
Thermal Conductivity 0.415098 W/m-K
Specific Heat 3681.92 J/ kg-K
Density 1015.57 kg/m3
Dynamic Viscosity 0.000744 Pa-s
Coolant Temperature In 105 °C
Coolant Temperature Out 40 °C
2|P age
Air Property Table (Fan)

The thermal fluid properties for the air is listed in the following.
Name of the Properties Properties Equivalent
Thermal Conductivity 0.0266 W/m-K
Specific Heat 1004.16 J/ kg-K
Density 1.13731 kg/m3
Dynamic Viscosity 0.00001912 Pa-s
Air Temperature In 25 °C
Air Temperature Out 60 °C
Solving for Areas Total:

Area of where the coolant flows:
𝐴𝑐 = (𝑁𝑜. 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠)[2(𝑇ℎ × 𝑅𝑙 )] + [2(𝑇𝑤 × 𝑅𝑙 )]

𝐴𝑐 = (28)[2(0.025 × 0.6)] + [2(0.0015 × 0.6)]
𝑨𝒄 = 𝟎. 𝟖𝟗𝟎𝟒 𝒎𝟐
Area of where the air flows:
𝐴𝑎 = (𝑁𝑢𝑚𝑜𝑓𝐴𝑖𝑟𝑃𝑎𝑠𝑠𝑎𝑔𝑒𝑠 )[2(𝐹𝑑 × 𝐹ℎ )] + [2(𝐹ℎ × 𝐹𝑤 )]

𝑅𝑙
𝑁𝑢𝑚𝑜𝑓𝐴𝑖𝑟𝑃𝑎𝑠𝑠𝑎𝑔𝑒𝑠 = (𝑁𝑢𝑚𝑜𝑓𝑡𝑢𝑏𝑒𝑠 − 1)
𝐹𝑑
0.6
𝐴𝑎 = ((28 − 1) ) [2(0.0015 × 0.014)] + [2(0.014 × 0.025)]
0.0015
𝑨𝒂 = 𝟖. 𝟎𝟏𝟑𝟔 𝒎𝟐
𝐴𝑡𝑜𝑡𝑎𝑙 = 𝐴𝑐 + 𝐴𝑎
𝐴𝑡𝑜𝑡𝑎𝑙 = 𝟎. 𝟖𝟗𝟎𝟒 𝒎𝟐 + 𝟖. 𝟎𝟏𝟑𝟔 𝒎𝟐
𝑨𝒕𝒐𝒕𝒂𝒍 = 𝟖. 𝟗𝟎𝟒 𝒎𝟐
3|P age
Solving for convection heat-transfer coefficient of the Fluids:

Convection heat-transfer coefficient of the coolant flows:
The value of hc depends on the physical and thermal fluid properties, fluid velocity
and fluid geometry. The Reynolds Equation defined below can be used to determine
the flow characteristics of the coolant as it passes through the tubes.
𝝆𝒗𝑫𝑯 4 𝐴𝑚𝑖𝑛 𝑉𝑓𝑐
𝑹𝒆 = 𝐷𝐻 = 𝑉𝐶 =
𝝁 𝑊𝑝 (𝑛𝑜. 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠)𝐴𝑚𝑖𝑛
3
4 (𝑇𝑤 × 𝑇ℎ ) 0.0018927 𝑚 ⁄𝑠
𝐷𝐻 = 𝑉𝐶 =
2(𝑇𝑤 + 𝑇ℎ ) (28)(0.0000375 𝑚2 )
4 (0.0015 × 0.025) 𝑽𝑪 = 𝟏. 𝟖𝟎𝟐𝟔 𝒎⁄𝒔
𝐷𝐻 =
2(0.0015 + 0.025)
4 (0.0000375 𝑚2 )
𝐷𝐻 =
0.053 𝑚
𝑫𝑯 = 𝟎. 𝟎𝟎𝟐𝟖𝟑 𝒎
𝜌𝑣𝐷𝐻 For fluids that are in turbulent flow (that is, Reynolds
𝑅𝑒 = Num > 5000), we can use the Dittus Boelter Equation
𝜇
to relate the Reynolds Num with the Nusselt Num. The
(1015.57)(1.8026)(0.00283) Nusselt Num is dependent upon the fluid flow
𝑅𝑒 = conditions and can generally be correlated with the
0.000744
Reynolds Num. Solving for the Nusselt Num will enable
𝑹𝒆 = 𝟔𝟗𝟔𝟑. 𝟒𝟐 (𝑡𝑢𝑟𝑏𝑢𝑙𝑒𝑛𝑡 𝑓𝑙𝑜𝑤) us to determine the value of hc.
𝐶𝜇 Using Dittus Boelter Equation

𝑃𝑟 =
𝑘 𝑵𝒖 = 𝟎. 𝟎𝟐𝟑 (𝑹𝒆)𝟎.𝟖 (𝑷𝒓)𝟏/𝟑
(3681.92)(0.000744)
𝑃𝑟 = 𝑁𝑢 = 0.023 (𝟔𝟗𝟔𝟑. 𝟒𝟐 )0.8 (𝟔. 𝟔𝟎𝟏)1/3
0.415098
𝑷𝒓 = 𝟔. 𝟔𝟎𝟏 𝑵𝒖 = 𝟓𝟏. 𝟏𝟗
𝒉𝒄 𝑫𝑯
𝑵𝒖 =
𝒌
𝑁𝑢 𝑘 𝟓𝟏. 𝟏𝟗 (0.415)
ℎ𝑐 = =
𝐷𝐻 0.00283
𝑾
𝒉𝒄 = 𝟕𝟓𝟎𝟔. 𝟔𝟔
𝒎𝟐−𝑲
4|P age
Solving for convection heat-transfer coefficient of the Fluids:

Convection heat-transfer coefficient of the air flows:
The value of ha depends on the physical and thermal fluid properties, fluid velocity
and fluid geometry. The Reynolds Equation defined below can be used to determine
the flow characteristics of the air as it passes through the fins.
𝝆𝒗𝑫𝑯 4 𝐴𝑚𝑖𝑛 Given Velocity of Air:
𝑹𝒆 = 𝐷𝐻 =
𝝁 𝑊𝑝 𝑽𝒂 = 𝟒. 𝟒𝟕𝟎𝟒 𝒎⁄𝒔
4 (𝑇𝑤 × 𝑇ℎ )
𝐷𝐻 =
2(𝑇𝑤 + 𝑇ℎ )
4 (0.025 × 0.014)
𝐷𝐻 =
2(0.025 + 0.014)
4 (0.00035)
𝐷𝐻 =
0.078 𝑚
𝑫𝑯 = 𝟎. 𝟏𝟕𝟗𝟓 𝒎
𝜌𝑣𝐷𝐻 For fluids that are in turbulent flow (that is, Reynolds
𝑅𝑒 = Num > 5000), we can use the Dittus Boelter Equation
𝜇
to relate the Reynolds Num with the Nusselt Num. The
(1.13731)(4.4704)(0.1795) Nusselt Num is dependent upon the fluid flow
𝑅𝑒 = conditions and can generally be correlated with the
0.00001912
Reynolds Num. Solving for the Nusselt Num will enable
𝑹𝒆 = 𝟒𝟕𝟕𝟑𝟏. 𝟏𝟒 (𝑡𝑢𝑟𝑏𝑢𝑙𝑒𝑛𝑡 𝑓𝑙𝑜𝑤) us to determine the value of hc.
𝐶𝜇 Using Dittus Boelter Equation

𝑃𝑟 =
𝑘 𝑵𝒖 = 𝟎. 𝟎𝟐𝟑 (𝑹𝒆)𝟎.𝟖 (𝑷𝒓)𝟏/𝟑
(1004.16)(0.00001912)
𝑃𝑟 = 𝑁𝑢 = 0.023 (𝟒𝟕𝟕𝟑𝟏. 𝟏𝟒)0.8 (𝟎. 𝟕𝟐𝟐)1/3
0.0266
𝑷𝒓 = 𝟎. 𝟕𝟐𝟐 𝑵𝒖 = 𝟏𝟏𝟒. 𝟏𝟖𝟔
𝒉𝒂 𝑫𝑯
𝑵𝒖 =
𝒌
𝑁𝑢 𝑘 𝟏𝟏𝟒. 𝟏𝟖𝟔 (0.0266)
ℎ𝑎 = =
𝐷𝐻 0.1795
𝑾
𝒉𝒂 = 𝟏𝟔
𝒎𝟐−𝑲
5|P age
Solving for LMTD for Cross-Flow Heat Exchanger:

Formula of Heat Transfer for Cross-Flow Heat Exchanger
𝑸 = 𝑼𝑨(𝑳𝑴𝑻𝑫𝑪𝑭 )
𝑸 = 𝑼𝑨[𝑭(∆𝑻𝒍𝒎𝑪𝑭 )]
∆𝑇1 − ∆𝑇2 45 − 15 ∆𝑻𝟏 = 𝒕𝟏 − 𝑻𝟐 ∆𝑻𝟐 = 𝑻𝟐 −𝒕𝟏

∆𝑇𝑙𝑚𝐶𝐹 = =
∆𝑇 45
𝑙𝑛 ( 1 ) 𝑙𝑛 ( ) ∆𝑻𝟏 = 𝟏𝟎𝟓 − 𝟔𝟎 ∆𝑻𝟐 = 𝟒𝟎 − 𝟐𝟓
∆𝑇2 15
∆𝑻𝒍𝒎𝑪𝑭 = 𝟐𝟕. 𝟑𝟎 𝑲 ∆𝑻𝟏 = 𝟒𝟓 ∆𝑻𝟐 = 𝟏𝟓
𝑡2 − 𝑡1 40 − 105 𝑳𝑴𝑻𝑫𝑪𝑭 = 𝑭(∆𝑻𝒍𝒎𝑪𝑭 )

𝑃= = = 0.8
𝑇1 − 𝑡1 25 − 105
𝑳𝑴𝑻𝑫𝑪𝑭 = 𝟎. 𝟖𝟓(𝟐𝟕. 𝟑𝟎)
𝑇1 − 𝑇2 25 − 60
𝑅= = = 0.5 𝑳𝑴𝑻𝑫𝑪𝑭 = 𝟐𝟑. 𝟐𝟏 𝑲
𝑡2 − 𝑡1 40 − 105
𝑸 = 𝑼𝑨(𝑳𝑴𝑻𝑫𝑪𝑭)
𝐴(𝐿𝑀𝑇𝐷𝐶𝐹 )
𝑄=
1 1 𝑥𝑡𝑢𝑏𝑒𝑠 𝑥𝑓𝑖𝑛𝑠
ℎ𝑐 ℎ𝑎 + 𝑘𝑡𝑢𝑏𝑒𝑠 + 𝑘𝑓𝑖𝑛𝑠
+
𝟖. 𝟗𝟎𝟒 𝒎𝟐 (𝟐𝟑. 𝟐𝟏 𝑲 )
𝑄=
1 1 0.00025𝑚 0.00005𝑚
+ + +
7506.66 𝑊/(𝑚^2 − 𝐾) 16 𝑊/(𝑚^2 − 𝐾) 237 W/m − K 180 W/m − K
𝑸 = 𝟑𝟐𝟗𝟗. 𝟒𝟗 𝑾
6|P age

Car Radiator Design Calculations

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VI.

Radiator Model Dimensions

Name Dimension in SI Unit

Radiator Length 0.6 m

Radiator Width 0.4 m

Radiator Height 0.025 m

Tube Height 0.025 m

Tube Width 0.0015 m

Fin Height 0.014 m

Fin Width 0.025 m

Distance Between Fins 0.0015 m

Number of Tubes 28 tubes

Fin Thickness 0.0005 m

Tube Thickness 0.000025 m

Radiator Operating Conditions

Name Operating Conditions

Coolant Volumetric Flow 0.0018927 m3/s

Air Volumetric Flow 1.10860 m3/s

Air Velocity (Fan) 4.47 m/s

Aluminum Thermal Conductivity (Tubes) 237 W/m-K

Carbon Foam (Graphite) Thermal Conductivity

Coolant Property Table (Glycol-Water)

Name of the Properties Properties Equivalent

Thermal Conductivity 0.415098 W/m-K

Specific Heat 3681.92 J/ kg-K

Density 1015.57 kg/m3

Dynamic Viscosity 0.000744 Pa-s

Coolant Temperature In 105 °C

Coolant Temperature Out 40 °C

Air Property Table (Fan)

Name of the Properties Properties Equivalent

Thermal Conductivity 0.0266 W/m-K

Specific Heat 1004.16 J/ kg-K

Density 1.13731 kg/m3

Dynamic Viscosity 0.00001912 Pa-s

Air Temperature Out 60 °C

Solving for Areas Total:

𝐴𝑐 = (𝑁𝑜. 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠)[2(𝑇ℎ × 𝑅𝑙 )] + [2(𝑇𝑤 × 𝑅𝑙 )]

Area of where the air flows:

𝐴𝑎 = (𝑁𝑢𝑚𝑜𝑓𝐴𝑖𝑟𝑃𝑎𝑠𝑠𝑎𝑔𝑒𝑠 )[2(𝐹𝑑 × 𝐹ℎ )] + [2(𝐹ℎ × 𝐹𝑤 )]

Solving for convection heat-transfer coefficient of the Fluids:

𝐶𝜇 Using Dittus Boelter Equation

Solving for convection heat-transfer coefficient of the Fluids:

𝐶𝜇 Using Dittus Boelter Equation

Solving for LMTD for Cross-Flow Heat Exchanger:

∆𝑇1 − ∆𝑇2 45 − 15 ∆𝑻𝟏 = 𝒕𝟏 − 𝑻𝟐 ∆𝑻𝟐 = 𝑻𝟐 −𝒕𝟏

𝑡2 − 𝑡1 40 − 105 𝑳𝑴𝑻𝑫𝑪𝑭 = 𝑭(∆𝑻𝒍𝒎𝑪𝑭 )

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