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    Cfd03 thermal analysis-of-automotive-lumax Cfd03 thermal analysis-of-automotive-lumax Document Transcript

    • Thermal Analysis of Automotive Head Lamp Using CFD Analysis Mr. Lalit Ahuja Mr. Vaibhav Wakchaure Deputy General Manger CAE Engineer Lumax Industries Ltd. Lumax Industries Ltd. Chakan, pune Chakan, pune AbstractThermal analysis of automotive lamps have become a significant part in the automotive industry’s design cycle due to the increaseddemand from the customers for more durable and energy efficient products. The life cycle of the light and the lamp components greatlydepend on the thermal management of the lamp system. Thermal analysis of the lamps not only helps to increase the life time of thelamp but also to determine its efficient operating conditions. This has been made possible with the increased growth in the field of CFD.Objective The objective is to find out the correct location of vent holes for hot air dissipation generated due tobulb radiations inside the chamber to avoid the impact of heat on the plastic parts. We have carried outthermal analysis of -Tata Motors SFC Head lamp using AcuSolve to find out the temperature distribution &heat flow developed due to bulb temperature and radiation through reflective surface inside the lamp.Introduction As per the vehicle mounting condition head lamp need to be placed in the ambient air for testing.Then the lamp is switched on as per std. for 24 hr. After testing period it is observed that the lampcomponent gets deformed due to high heat generated in the lamp and improper heat dissipation throughvent holes provided. The number of vent holes provided or location of vent hole provided is not sufficient forair circulation due to this hot air get trapped inside the lamp chamber and we observed deformation of lampcomponent. To overcome this failure we perform the CFD Analysis considering all three modes of heattransfer Conduction, Natural Convection and Radiation on head lamp Assembly.Process Methodology1) Geometry Import:We have imported the Geometry in HyperMesh-11. CAD geometry needs to be clean up and done easilywith the help of HyperMesh which is pre-processing tool.2) Meshing:We have created the water tight geometry for surface meshing using R-Tria in HM by closing the vents.Then we import surface mesh model in AcuSolve 1.8-b. We create the Volume mesh in AcuConsole veryeasily with boundary layer mesh across the heat source (Bulb) for better flow of visualization and capturetemperature gradients around the bulb.Simulation Driven Innovation 1
    • 3) Boundary Condition:-We have assigned the material property for lamp component and temperature for heat source. we alsoconsidered the outside temperature for analysis for the components which are exposed to the atmosphere. 4) Post Processing:-For viewing the results we have used HyperView. Temperature plot on components, air flow through ventholes, air flow inside of lamp are observed.Results & Discussion After getting results from AcuSolve we have exported the result data which is numerical format toHyperView for post-processing.Post-Processing: Fig. 1: Temperature Counter on Head Lamp with new CADSimulation Driven Innovation 2
    • Fig.2: Temperature Counter on Head Lamp with old CAD Fig.3: Path Lines Counter on Head Lamp with new CADSimulation Driven Innovation 3
    • Fig 4: Velocity Counter on Head Lamp with new CADBefore CFD: Base Cad Model Improvement locationSimulation Driven Innovation 4
    • After CFD: Optimized Cad Model Improved locationAs shown in above picture we made changes in the cad geometry and done the analysis. We increased thenumber of vent holes and changed the location of vent holes for proper ventilation through lamp. This isanalyzed and validated for both thermal and structural vibrations.Benefit SummaryMeshing of plastic parts is really typical. As we look into our Product – It is very complicated, specially theReflector and the Housing. HyperMesh helped us for meshing such complicated components with ease. forair mesh and boundary layer mesh we use AcuSolve which is required very less time .After the Analysis wefound vent hole location is not accurate for air circulation we modify the location and also we modify thematerial of component which can withstand the high temperature. Using HyperMesh along with AcuSolvewhich has been successful solution for the above problem.ChallengesDefect free launch and to overcome from Warranty issue later due to heat and field failure. To avoid MajorMaterial change later, if it fails. Having large reflectors in the head lamp, heat generated will be high so itscontrol and proper dissipation is another challenge.Simulation Driven Innovation 5
    • Future Plan Now in future we have introduced CFD Analysis as a part of Design Process during the Product DesignStage. This helps us in validating the Product virtually and ensures good quality and Cost effective Productbefore creating any Physical proto samples. And also to run a transient analysis to simulate the ON-OFFcondition for the lamps.Conclusion As per the analysis results, we found for Hot air circulation we required more vent hole with accuratelocation and also we have changed Grade of the material having the HDT value.Simulation Driven Innovation 6