Multi-scale thermal analysis approach for the typical heat exchanger in automotive cooling systems

CFD/CHT simulations have been widely used in simulating cross flow compact heat exchangers, but the calculating accuracy is commonly limited. The multi-scale thermal analysis approach was adopted to study an intercooler, one of the representative examples of cross flow heat exchangers in automotive cooling systems. With the application of mesh refinement and datum interpolation technique, the inside flow and heat transfer mechanism were analyzed, the pressure and temperature data were also calculated. The model was validated with experimental data based on wind tunnel tests, and the results show that the multi-scale coupled calculation is in good agreement with experimental values, especially in the heat transfer simulations. The research of the inside flow and heat transfer mechanism is capable of providing a basis for optimization of compact heat exchangers.