Numerical simulation of immersion quenching process of an engine cylinder head

In this article, we present the numerical simulations of a real cylinder head quench cooling process employing a newly developed boiling phase change model using the commercial CFD code AVL-FIRE v8.5. Separate computational domains constructed for the solid and liquid regions are numerically coupled at the interface of the solid–liquid boundaries using the AVL-Code-Coupling-Interface (ACCI) feature. The boiling phase change process triggered by the dipping hot metal and the ensuing two-phase flow is handled using an Eulerian two-fluid method. Multitude of flow features such as vapor pocket generation, bubble clustering and their disposition, are captured very effectively during the computation, in addition to the variation of the temperature pattern within the solid region. A comparison of the registered temperature readings at different monitoring locations with the numerical results generates an overall very good agreement and indicates the presence of intense non-uniformity in the temperature distribution within the solid. Overall, the predictive capability of the new boiling model is well demonstrated for real-time quenching applications.