Mechwell Industries provides engineering services including computational fluid dynamics (CFD) analysis. They analyzed the performance of an exhaust gas recirculation (EGR) cooler using CFD to determine the heat transfer rate and pressure drops on the gas and coolant sides. They created 3D models of the gas and coolant sections, applied boundary conditions and material properties, then simulated the flows. The CFD analysis found the gas side had a 5 kPa pressure drop and outlet temperature of 99°C, while the coolant side had a 0.5 kPa pressure drop and outlet temperature of 205°C, determining the heat transfer between the sections.

1. CFD Analysis Of Oil Cooler.
About Mechwell Industries Limited
Mechwell is a Innovation based Engineering Service providing company with a team
of expert engineering discipline. The core of our business is to assist fast growing industry by
providing turnkey solutions. We provide engineering services in the field of Computer Aided
Design(CAD), Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA) for
individuals, companies as well as for Research & Development Projects. Mechwell Industries
also has a core vision of Creating Lean Industries with the best competency towards a new era
of industrial revolution. With this purpose, we have different Process Engineering and Plant
Analysis services such as Plant Simulation & Design, 2D & 3D Plant Layout Design, Process
Flow Design, Inventory management, Design validation and Value Stream Mapping. We are
also Manufacturers and suppliers of Expansion Joints , Dampers and Gates and carry out full
fledge Testing Services for ensuring Plant optimization.
Computational Fluid Dynamics Services –
CFD solutions give you the potential to model and simulate all fluid processes so you
can have confidence that your product will perform optimally before you make the first
prototype. Our strong CAE team do it for you. We are offering Single Phase Flow Analysis,
Multiphase Flow Analysis, Fluid Flow Analysis, Heat Transfer Analysis, Turbo Machinery,
Hydrodynamic Analysis, Fluid Structure Interaction in the industry of Aerospace, Power,
Cement Building Ventilation, Heat Exchangers, Heating/Refrigeration and Separation &
Mixing.
Problem Aim:
1. To find the performance of the
EGR Cooler.
2. To find the Heat Transfer Rate of
the EGR Cooler.
3. To find out Pressure drop from
Gas Side & Coolant side.
4. To find out flow separation point.
Inputs :
 CAD model or 2D drawings for
selection of the computational
domain.
 Boundary Condition.
 Material Property – density , thermal
conductivity, specific heat.
Deliverable:
 Contour plots and vector plots.
 Technical information pressure drop
& temperature drop & heat transfer
coefficient.
 Graphics and animations.
 Provide optimization in geometry
without compromising in efficiency.
Methodology/ Procedure:
Prepare a 3 D model.
Grid generation using ANSYS
software.
Analysis is divided into two parts:
Simulation of Gas side which consist
of tray with slots and analyze the tray
and check its tempreture,pressure
profile.
Similarly, simulation of oil coolant
side analyze its flow velocity.
temperature & pressure profile by
which we find the how much heat is
transferred.

2. 3 D model and Meshing OF Gas Side:
GAS
IN
GAS
OUT
approx 5 million elements
Results:
Velocity, temperature and pressure contours of flow distribution in gas tray.
(A)
(B)
(C)
Conclusion:
Velocity contour plot shows flow distribution in the tray. We can see
the flow is passing through the shortest path.
Temperature plot shows thermal distribution in the tray. Flow is
passing through the shortest path and temperature at outlet is 99 deg C.
Pressure plot shows pressure distribution in the tray. Pressure drop
across the system is 5 KPa.

3. Meshing of oil side:
Results:
Velocity, temperature and pressure contours of flow distribution in gas tray.
(A)
(B)
(C)
Conclusion:
Pressure plot shows pressure distribution in the tray. Pressure drop
across the system is 0.5 K Pa
Velocity vector plot shows flow distribution in the tray.
Temperature plot shows thermal distribution in the tray. Temperature
at outlet 205 deg C
Mesh details:- approx 1.50 million elements