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Design Analysis and Fabrication of an Automotive Radiator

A thesis submitted to the department of Mechanical and Chemical Engineering (MCE), Islamic University of Technology (IUT), in the partial fulfillment of the requirement for the degree of Bachelor in Science in Mechanical Engineering.

Prepared By K. M. Safat Rashif (071409) Md. Abid Al Rabbi (071418) Izaz Ul Mulk (071443)

Supervised By Dr. Mir Md. Maruf Morshed

Department of Mechanical and Chemical Engineering Islamic University of Technology The Organization of Islamic Cooperation (OIC) 1

Declaration: This is to certify that the work presented in this thesis is an outcome of the experiment and research carried out by the authors under the supervision of Dr. Mir Md. Maruf Morshed.

__________________ K. M. Safat Rashif (Author) Date:

__________________ Md. Abid Al Rabbi (Author) Date:

__________________ Izaz Ul Mulk (Author) Date:

__________________ Dr. Mir Md. Maruf Morshed (Project Supervisor) Date:

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Acknowledgements:
The project was carried out by the authors under the close supervision of Dr. Mir Md. Maruf Morshed, Assistant Professor, Department of Mechanical and Chemical Engineering, Islamic University of Technology (IUT). The supervisor had dedicated his valuable time, even at odd hours, which had ensured the completion of this project. We express profound gratitude to the supervisor for his support, cooperation and guidance in accomplishing the project. I would like to express my sincere gratitude towards Md. Rabiul Hassan, Md. Abul Kashem and Md. Abdul Motalib, Lab Instructors, Department of Mechanical and Chemical Engineering. Without their co-operation, it would have been very difficult for us to complete the project successfully.

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CONTENTS

Abstract ……………………………………………………………………………………………………….. 05 Information search ………………………………………………………………………………………. 06 Limitations …………………………………………………………………………………………………… 08 Case studies ………………………………………………………………………………………………... 08 Concept Generation …………………………………………………………………………………….. 10 New radiator designs ……………………………………………………………………………………. 12 Latest model of copper radiator ……………………………………………………………………. 14 Limitation of the model ………………………………………………………………………………… 14 Aluminium vs Copper ……………………………………………………………………………………. 15 Why copper is used? …………………………………………………………………………………….. 16 New design ……………………………………………………………………………………………………. 16 Elements used ………………………………………………………………………………………………. 17 Stages ……………………………………………………………………………………………………………. 17 Full set-up ……………………………………………………………………………………………………… 21 Design parameters ………………………………………………………………………………………… 22 Use of vortex generator ………………………………………………………………………………… 22 Fabricating components ……………………………………………………………………………….. 24 Formulas used ………………………………………………………………………………………………. 24 Comparison table ………………………………………………………………………………………….. 25 Comparison graph …………………………………………………………………………………………. 26 References ……………………………………………………………………………………………………. 27

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Abstract:
Radiators are installed in automobiles to remove heat from under the hood. Our task is to design an automotive radiator to work in high temperature. The new radiator design can be used in new hybrid vehicles as well as in CNG operated vehicles. These hybrid vehicles have multiple cooling systems for the internal combustion engine, electric engine, and batteries. New radiator design, can possibly replace these multiple cooling systems.

Figure: Automotive Radiator

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Information Search:
The first step of this project was to gather information on existing radiator designs and general heat exchangers. After gathering information, we gained a thorough understanding of how a radiator works and the disadvantages of the current radiator designs. This included a general patent search, using Google Scholar, and technical journal search, using Compendex, that related to radiators. Once we choose our design, we must research a general testing method to use as a basis for our comparison of our...
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