Abstract
During the development of automobile it was a bigger challenge to prevent the engine & engine components from melting & damages because the heat generated & temperature inside the cylinder is more than the melting points of engine components due to combustion of fuel inside the cylinder. Many researchers & scientist started working for making the arrangement to dissipate the heat of considerable amount to avoid such bigger problem otherwise engine will seize. After a lot of research work on different types of materials to conduct the heat efficiently they came to conclusion that copper is the best material having good thermal conductivity of 385 watt/m-K can be used in the form of heat exchanger & finally they designed a radiator called COPPER RADIATOR. It is in continuous use in all types of automobile across the world. Over a period due to various pressure of availability, manufacturability, performance, reliability, cost, handling, weight researchers started working on use of alternate materials in a radiator in place of copper to match the performance same as copper & getting other benefits. Attempts have been tried on different kinds of materials & finally found that can solve our problem & it will meet most of our objectives & requirements. So, finally it has been decided to make Aluminium in place of Copper radiators which will give benefits in performance, reliability, cost, availability, easy in handling & manufacturing. The design & development techniques will be discussed subsequently. The effort of this project is to replace the costly copper radiator used in automobile by radiator for better reliability, cost benefit, weight reduction & desirable performance. The radiator has a number of features that make it very attractive for vehicle applications in general. Superior durability and reliability in conjunction with its excellent specific values for costs, performance and weight warrant a favorable solution for Heavy Duty Trucks, tractors, Car, earth movers & other Automobile segments. This methodology examines the results based on design, lab testing, and field testing in actual condition. It reviews the field experience compared to Copper/Brass radiators, examines design and mounting features. Durability, external and internal corrosion resistance are emphasized as essential characteristics. A special focus is the thermodynamics of radiators. The result obtained has been summarized as below:(a) Radiator is able to transfer the heat of 27.95 KW same as Copper Radiator. This is the 1/3 rd amount of heat generated in the engine to be dissipated. (b) Cost Reduction of Amount Rs 1923/- it is about 49% saving against existing cost of Copper Radiator. (c) Weight Reduction of 5 Kg, it is 52.08% reduction in weight due to use of Radiator.(d) Reliability & Field Performance is as per copper Radiator, there is no field failure within the warranty period in all types of applications.
Highlights
As on current scenario due to unstable economic condition & continuously increasing in commodity prices like steel, petroleum, coal & minerals, electrical & electronic equipment’s & general purpose things the manufacturing cost of a product is getting increases Due to increase in cost & competitions between the competitors there is huge pressure in cost reduction & better quality to be pass to the customer to run the industries & stand in markets among all similar product.In automobile industries Radiator is a prime component of any vehicle like car, Bus & Truck, Tractors etc. & play very important role in the cost & performance of vehicle
The result obtained has been summarized as below:(a) Aluminium Radiator is able to transfer the heat of 27.95 KW same as Copper Radiator
This is the 1/3rd amount of heat generated in the engine to be dissipated. (b) Cost Reduction of Amount Rs 1923/- it is about 49% saving against existing cost of Copper Radiator. (c) Weight Reduction of 5 Kg, it is 52.08% reduction in weight due to use of Aluminium Radiator.(d) Reliability & Field Performance is as per copper Radiator, there is no field failure within the warranty period in all types of applications
Summary
As on current scenario due to unstable economic condition & continuously increasing in commodity prices like steel, petroleum, coal & minerals, electrical & electronic equipment’s & general purpose things the manufacturing cost of a product is getting increases Due to increase in cost & competitions between the competitors there is huge pressure in cost reduction & better quality to be pass to the customer to run the industries & stand in markets among all similar product. It is designed to transfer heat from the hot water flowing through it to the air blown through it by the fan These radiators are made by brazing thin Aluminium fins to flattened Aluminium tubes. Modern automotive internal combustion engines generate a huge amount of heat. This heat is created when the gasoline and air mixture is ignited in the combustion chamber. In a liquid cooled system, heat is carried away by the use of a heat absorbing coolant that circulates through the engine, especially around the combustion chamber in the cylinder head area of the engine block. The coolant is pumped through the engine, after absorbing the heat of combustion is circulated to the radiator where the heat is transferred to the atmosphere. An effective cooling system controls the engine temperature within a specific range so that the engine stays within peak performance
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