DESIGN AND FABRICATION OF CIRCULAR DIMPLED

RADIATOR
A PROJECT REPORT
Submitted by

ARVIND KUMAR.G
711711114009
ATHI NARAYANAN.M
711711114010
CHRISTOPHER CHARLES 71171111401
DEEPAK.D
711711114012
in partial fulfillment for the award of the degree
of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

KGiSL INSTITUTE OF TECHNOLOGY

ANNA UNIVERSITY::CHENNAI 600 025
APRIL 2014

ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE
Certified that this project report ....DESIGN AND FABRICATION
OF CIRCULAR DIMPLED RADIATOR..
is the bonafide work of

ARVIND KUMAR.G
711711114009
ATHI NARAYANAN.M
711711114010
CHRISTOPHER CHARLES 71171111401
DEEPAK.D
711711114012
who carried out the project work under my supervision.

SIGNATURE

SIGNATURE

Mr. Venkataraman.,M.E (Ph.D)

JUDSON JOSHUARAJ B.E. MBA.,

HEAD OF THE DEPARTMENT (i/c)

SUPERVISOR

Associate Professor

Assistant Professor

Department of Mechanical Engineering

Department of Mechanical Engineering

KGiSL INSTITUTE OF TECHNOLOGY

COIMBATORE-641035

KGiSL INSTITUTE OF TECHNOLOGY

COIMBATORE-641035

Internal Examiner

External Examiner

ACKNOWLEDGMENT
We express our deepest gratitude to our CHAIRMAN AND MANAGING
DIRECTOR for providing us with an environment to complete our project
successfully.
We are very grateful to our Dr.R.Ravichandran Ph.D.,Director and
Dr.M.Rajendran., Ph.D., Principal for their valuable guidance and blessings.
We would like to thank Mr.K.Venkataraman.M.E (Ph.D) .,Head of the
Dept(i/c) for his unwavering support during the entire course of this project first
phase work and who modeled us both technically and morally for achieving greater
success in this project work.
We express our sincere thanks to our guide Mr.Judson Joshuva raj
B.E,MBA for his constant encouragement and support throughout our course,
especially for the useful suggestions given during the course of the project period
and being instrumental in the completion of our project with his complete
guidance.
We also thank all the Non teaching staff members of our college for their
help in making this project a successful one.
Finally, we take this opportunity to extend our deep appreciation to our
family and friends, for all that they meant to us during the crucial times of the
completion of our project.

ABSTRACT

Our Project FABRICATION OF CIRCULAR DIMPLE RADIATOR [Radiator as

heat exchanger] mainly focuses on the thermal design and analysis of radiator as heat exchanger
The project contains the design and material selection of the radiator for different type
of vehicles also. For better efficiency, improvement of heat transfer rate is important
phenomenon
Radiators are heat exchangers used for cooling internal combustion engines mainly in
automobiles. The main objective of the project is to increase the heat transfer rate by modifying
the rectangular shape radiator into circular shape radiator.
The object of work is to have a circular radiator which is compact made with
minimum. Material-less costly more efficient-that will work with minimum power consumption
of fan and maximum utilization of air flow.

INDEX

Acknowledgement
Abstract
Contents
List of figures
List of tables
List of symbols, abbreviations and Nomenclature

1. INTRODUCTION AND LITERATURE

INTRODUCTION
REVIEW

1.1 Introduction of heat exchanger

The present manufacturing of heat exchangers commonly used in
practice in Automobiles, Internal Combustion (IC) engines, Refrigeration systems, and
Power plants emphasizes on production process, materials and spacing of fins.

The heat transfer rate is increased from the fined surface to the surrounding
flowing fluid by creating a dimpled surfaces and pinfins. Both the combinations of circular
shape radiator and dimple surface on the pinfin which increases the heat transfer rate.

1.2 Types of heat exchanger and flow

configurations
One of the simplest designs for a heat exchanger is the double pipe heat exchanger
which is schematically illustrated in Fig. It consists of two concentric tubes, where fluid 1 flows
through the inner pipe and fluid 2 flows in the annular space between the two tubes. Two
different flow regimes are possible, either countercurrent where the two fluids flow in opposite
directions, or concurrent as in Fig.

Figure1.1: Fluid temperatures 1 and 2 in a double-pipe heat exchanger. a countercurrent

flow, b concurrent flow

In practical applications the shell-and-tube heat exchanger, as shown in Fig. is the most
commonly used design. One of the fluids flows in the many parallel tubes which make up a tube
bundle. The tube bundle is surrounded by a shell. The second fluid flows around the outside of
the tubes within this shell. Countercurrent flow can be realized here except at the ends at of the
heat exchanger where the shell side fluid enters or leaves the exchanger. The addition of baffles,
as in Fig., forces the shell side fluid to flow perpendicular to the tube bundle, which leads to
higher heat transfer coefficients than those found in flow along the tubes. In the sections between
the baffles the fluid is neither in counter or concurrent flow but in cross flow.

Figure1.2: Shell-and-tube heat exchanger (schematic)

These above all are main classification of the heat exchanger but these heat
exchangers are also classified according to many ways some of them are shown as below.

2.RADIATOR

2.1 Introduction of Radiators

Radiators are heat exchangers used for cooling internal

combustions, mainly in automobiles but also in piston engine aircraft, railway
locomotives, motor cycles, stationary generating plantor any similar use of an
engine.
It is designed to transfer heat from the hot coolant that flows through it
to the air blown through it by the fan .Mostly modern car use aluminium radiators.
These radiators are made by brazing thin aluminium fins to flattened aluminium
tubes. The fins conduct the heat from the tubes and transfer it to the air flowing
through the radiator.

2.2 Auto Radiators and Car Parts Cooling System Glossary

Belt: Your cooling system uses an engine belt to drive the blower fan. Some cars have an additional
electric motor to force air over the auto radiators cores.
Blower/Blower Motor: the fan assembly that pushes air across the cooling cores of your car radiator.
Coolant: The standard mix of anti-freeze and water used for cooling automobile engines.
Coolant Overflow Tank: When your car gets hot, the coolant expands and partially fills the coolant
overflow tank. This is normal.
Fan: See Blower.
Heater Core: The opposite of the auto radiator's cooling core. It uses hot coolant coming from the
engine to heat air for your car's heater.
Hoses: All car radiators use several hoses to pass the coolant to and from the engine. They are affixed to
the auto radiator and engine with hose clamps.
Oil Cooler: It is a secondary cooling system used in cars with automatic transmissions. It cools the oil
from the automatic transmission.
Auto Radiators: The grid of specially shaped metal tubes behind the grill of your car. Hot coolant
passes through these cores and is cooled by the air passing over them. This is the principal method of
cooling an internal combustion engine and the car parts involved.
Radiator Cap: The pressure sensitive radiator cap on the top of your radiator. It increases the pressure in
your cooling system, allowing more efficient cooling. The radiator cap is also designed to expel excess
pressure caused from the coolant becoming too hot or boiling. This prevents damage to the cooling
system.

Thermostat: This regulates the flow of coolant through the engine. It only opens when the engine gets
hot enough, allowing your engine to heat up quickly (good in the winter!).
Transmission Oil Cooler: See Oil Cooler.
Water Pump: This pump forces the coolant through the cooling system.

Figure:2.1 Coolant path and Components of an Automobile Engine Cooling System

2.3 FUNCTIONS OF RADIATOR

A radiator is a type of heat exchangers.It is designed to transfer heat from the hot coolant
that flows through to the air blow through it by the fan.

The fin conduct the heat from the tubes and transfer it to the air flowing
the radiator.

The radiator cools the water that flows around the engine.it helps to cool
liquids that exist in engine.

Radiators also holds coolant to speed cooling process of liquids.

Car radiators made by aluminium. Because aluminum does not rust.

2.4 CIRCULAR SHAPE RADIATOR

Normally radiators are in rectangular or in square in shape, therefore in this

case heat transfer rate does not takes place uniformly. In order improve the heat transfer rate in
car radiators the shape of a radiators are modified into circular shape. Due to this circular shape
uniform heat transfer rate takes place.

FIGURE: 2.2 Proposed Heat Exchanger (Radiator)

2.5 ADVANTAGES OF CIRCULAR SHAPE RADIATORS OVER

RECTANGULAR SHAPE RADIATORS

Compact in shape

Made with minimum material

Low cost

More efficient

Minimum power consumption

Maximum utilization of air flow

3.PIN FIN

3.1 Introduction of PIN FIN

A fin is a surface that extends from an object to increase the rate of heat transfer to or from
the environment by increasing convection. The amount of conduction, convection, or radiation of an
object determines the amount of heat it transfers. Increasing the temperature difference between the
object and the environment, increasing the convection heat transfer coefficient, or increasing the surface
area of the object increases the heat transfer. Sometimes it is not economical or it is not feasible to
change the first two options. Adding a fin to an object, however, increases the surface area and can
sometimes be an economical solution to heat transfer problems.

FIGURE 3.1

3.2 LONGITUDINAL FIN

Rectangular

Trapezoidal

Triangular

Concave parabolic

Convex parabolic

3.3 FUNCTIONS OF FINS

To increase the surface area of the metal body which provides cooling.

It increases the efficiency to the maximum cooling effect

To speed up the transfer of heat energy

3.4 Dimpled surface pinfin

A tremendous amount of effort has been devoted to developing new
methods to increase heat transfer from fined surface to the surrounding flowing fluid. Rib
turbulators, an array of pin fins, and dimples have been employed for this purpose.

There are two different types of dimples: 1) circular (spherical)

dimples, and 2) oval (elliptical) dimples. Dimples were placed on both sides of a copper plate
with a relative pitch of S/D=1.20 and relative depth of /D=0.2 (e.g., circular dimples). For oval
dimples, similar ratios with the same total depth and circular-edge-to-edge distance as the
circular dimples were used.

Fig.. Experimental Set-up

Fig.. Schematic drawings, (a) the entire test surface of the flat copper plate; (b) the entire test
surface of the circular type copper plate with dimple dimensions ; (c) the entire test surface of
the oval (elliptical) type copper plate with dimple dimensions. All dimensions are given in mm.

4. DESIGN CALCULATION

The dimpled surface on the pinfin will increase the heat transfer rate in the car radiators by
means of giving a high efficiency cooling effect.

CALCULATION
4.1 INPUT:
Mass flow rate through water jacket(kg/sec)(mc) = 0.35
Mass flow rate through air (kg/sec)(ma) = 10.66
Coolant temperature at radiator inlet (Tci) = 383k
Coolant temperature at radiator outlet (Tco) = 316k
Ambient inlet air temperature (Tai )= 298K
Specific capacity of air (cpa) = 1005J/Kgk
Specific capacity of coolant (Cpc) = 3621.582J/Kgk

4.2 Solution:
Mass flow rate through water jacket (mc)=1250Kg/hr
=1250/3600
=0.35Kg/sec
Mass flow rate through air (ma)

= PV/RT
=1.013*10^5*9/287*298
=10.66 Kg/sec

Specific heat capacity of coolant (Cpc) = 0.865 (Btu/lbf)

At equilibrium condition and assuming the cooling air accurate for all heat loss from the
Radiator , it is to be expressed
Qa = Qc
Qa=heat carried by the air from the radiator
Qa = macpa ( Ta0-Tai )
Qc = heat carried by the coolant radiator
Qc = mccpc ( Tci-Tco )

Hence
Qa=Qc
Mccpc (Tci-Tc0) = macpa (Ta0-Tai)
7.927 = Ta0-298
Ta0=7.927+298
=305.927K
Where Ta0= outlet air temperature

4.3 ENGINE POWER INPUT

Qengine= 327.34Kw
Heat loss in engine:
Total quantity of heat converted in engine that is lost to cooling water
Qengine= mCPT
Qengine= Qradiator

Cooling surface heat transfer area (As) = Qradiator / hc (Tf-Ts)

Coolant side temperature (Ts) or Average wall surface temperature of radiator (k) = 310k
Mean fluid temperature between coolant inlet and outlet temperature (Tf) (k) = 363k
4.4 NUSSELT NUMBER
hc = 1.155 ( 1 + 1.24 Cm ) ( p2 T )^0.67
Cm = mean piston speed = 10 m/s
P = 1 atm
T = 365 K
T = Tavg

hc = 803.20 w/m2 k

As = Qradiator / hc ( Tc Ts )
= 327.34*10^3 / 803.20 ( 363-310 )
As = 7.690 m2

/4 d2 = 7.690
d2 = 9.796
d = 3.130 m

4.5 FIN DETAILED CALCULATION:

From various journals the following readings are taken:

Fin area (A)

= 30*300.

Thermal conductivity of aluminium (K)

= 227 W/Mk.

Surface temperature of fin (Ts)

= 373K.

Ambient temperature (T)

= 300K.

Convective heat transfer co-efficient for air (h)

= 20 W/M2k.

Thermal design power (Q)

= 327.34 KW.

FORMULA FROM HMT DATA BOOK:

Qfin

= (hpkA)0.5(TB-T)tanh(ml).

Qwithout fin

= hA (TB-T).

= tanh (ml)/ml.

Fin effectiveness (E)

= Qfin/ Qwithout fin .

Various fin calculation are shown below:

Space between two radiator tubes

= 10mm.

Length of the fin

= 10 mm.

Width of the fin

= 30mm.

Thickness of the fin

= 1mm .

Space between the two fins

= 1mm.

Height of the radiator

= 380mm.

Number of tube used

= 30.

Number of fin

= 185

One end of fins touched to tube To

= 90oc.

One end of fin with ambient air Ta

= 54oc.

Heat lost by fins

= 1106.35 KW.

Fin efficiency

= 94%.

5. LIST OF FIGURES

S.NO FIGURE NO

DESCRIPTION
:

1.

2.

1.1
1.2

Fluid temperatures 1 and 2 in a doublepipe heat exchanger

Shell-and-tube heat exchanger (schematic)

3.

2.1

Coolant path and Components of an

Automobile Engine Cooling System

4.

2.2

Proposed Heat Exchanger (Radiator)

5.
6.
7.
8.
9.
10.

vii

PAGE
NO.

6. LIST OF SYMBOLS & NOMENCLATURE

SYMBOL USED
S.NO

PAGE NO