COOLING SYSTEM
Introduction
I.C Engines at best can transform about 25-30 % of the chemical
energy in to the fuel in to mechanical energy.
About 35 % of the heat generated is lost to the cooling medium
remainder being dissipated through exhaust and lubricating oil.
1/3 Heat to Useful Work
1/3 Heat to cooling System
1/3 Heat to exhaust system
Introduction
The Purpose of Cooling System
Prevent Overheating
Excess Heat generated in engine
Peak temperatures exceed melting point of metal
Regulate the most efficient Temperature
Regulate Temperature
Allow engine to warm up in cool weather
Maintain engine in optimum range.
Introduction
Consequence of engine running too hot:
Pre-ignition
Detonation/Knock
– All result in very high pressure rise and possible damage to engine
Heat Fatigue of components
Burnt Pistons
Burnt Valves
Failure of lubrication system
Oil breakdown
Oil film at cylinder destroyed at 200C
Scoring of piston & sleeves
Warping & fracture of components
Introduction
Consequence of engine running too cold:
Unnecessary Wear
Poor Fuel Economy
Incomplete Combustion
Lower coolant Temperature
More energy transferred out of cylinder
Energy from is wasted & not available for work (Power)
Promotes corrosive conditions in engine
Water of combustion reacts with sulfur oxides in exhaust
Forms acids
Allows water & sludge to accumulate in crankcase
Over time, fuel diluting the oil will accumulate
Normally lighter volatile fuel will evaporate as temp. rises
Introduction
Critical engine components that need to be
maintained at optimal designed temperature
Combustion chamber walls
Cylinder wall
Cylinder head
Piston
Exhaust valve
Spark plug
Gasoline / Diesel injector
Engine lubricants
Cooling system
Cooling System components Function
Centrifugal pump Cooling fluid circulation
Cooling fluid Heat transfer
Radiator Heat exchange with the ambient
Fan Air through the radiator at low vehicle
speed
Thermostat Engine temperature stabilization
Cooling system
Cooling System components Function
Expansion tank Fluid expansion and gas release
Filler pressure cap
Cooling circuit pressure
Passenger compartment radiator
Passenger compartment heating
Lubricant radiator
Engine lubricant cooling
EGR cooling radiator (Diesel)
Exhaust gas cooling
Cooling system
Heat transfer fluid Etilene glycol mixture in water (30 –60% concentration)
Water
High specific heat High thermal capacity
Low viscosity Low pressure drop
High heat of vaporization Low gas formation
Constant characteristics vs time and temperature
Etilene glycol Low freezing point
Cooling system
Ethylene glycol freezing point vs concentration in water
EG Weight Freezing Point Freezing Point
Percent (%) (deg F) (deg C)
0 32 0
10 25 -4
20 20 -7
30 5 -15
40 -10 -23
50 -30 -34
60 -55 -48
70 -60 -51
80 -50 -45
90 -20 -29
100 10 -12
Cooling system
General equation for engine thermal balance
Q f = Qu + Q w + Q g + Qi (kJ h)
where:
Qf= heat introduced into the engine through the fuel combustion
Qu = work equivalent heat at the engine shaft
Qw = heat realeased to the engine cooling system
Qg = heat rejected to the exhaust gases
Qi = lost heat for radiance
Introduction
Variation of Gas Temperature Piston Temperature Distribution
Introduction
Heat Transfer
As a result of combustion, high temperature are produced, inside
the engine cylinder
Considerable heat flow from the gases to the surrounding metal
walls
Shearing of the oil film
Heat transfer from gases to the cylinder walls may occur
predominantly by Convection & Radiation
Heat transfer through the cylinder wall occurs only by conduction
The temperature profiles across the cylinder barrel wall
For water cooled engine
Air cooled engine
Introduction
Cylinder wall temp profile
Parameters Affecting Engine Heat Transfer
Engine heat transfer depends upon many parameters, unless the effect of
these parameters is known, the design of a proper cooling system will be
difficult.
Fuel-Air Ratio
A change in fuel-air ratio will change the temperature of the cylinder gases and
affect the flame speed.
Spark Advance
More or less spark advance from the optimum value will result in increased heat
rejection to the cooling system
Pre-ignition and knocking
Engine output
Engines which are designed for high M.E.P or high piston speeds, heat rejection will
be less
Cylinder wall temperature
Characteristics of an efficient cooling system
The two main characteristics desired of an efficient
cooling system
It should capable of removing about 30 % of the heat
generated in the combustion chamber while maintaining the
optimum temperature of the engine under all operating
conditions of the engine
It should remove heat at a faster rate when engine is hot.
However during starting of the engine the cooling should be
minimum, so that the working parts of the engine reach their
operating temperatures in a short time
Types of cooling System
There are two types of system in general
Liquid or indirect cooling system
Air or direct cooling system
Liquid cooling system
Mainly water is used and made to circulate through the cooling
jackets provided around the cylinder, cylinder head, valve ports
and seats where it extracts most of the heat
The heat transferred from the cylinder wall and other parts by
convection and conduction
The heat from liquid in turn is transferred to air. Hence it is called
the indirect cooling system
Methods of water-cooling System
Water cooling can be carried out by any one of the
following five methods
Direct or non return system
Thermosyphon system
Forced circulation cooling system
Evaporation cooling system
Pressure cooling system
Direct or Non return System
This system is useful for large installations where plenty of
water is available.
The water from a storage tank is directly supplied through an
inlet valve to the engine cooling water jacket
The hot water is not cooled for reuse but simply discharged.
Thermosyphon System
Heat is supplied to the fluid in the tank A
Because of relatively lower density, the hot fluid travels up
Its place being taken up by comparatively cold fluid from the Tank B
through the pipe p2
The hot fluid flows through the pipe P1 to the tank B where it gets cooled
The fluid circulates through the system in the form of convection current
Thermosyphon System
Tank A –represents the cylinder jackets
Tank-B- represents a radiator and
water acts as the circulating fluid.
The advantages are
Its simplicity
Automatic circulation of cooling water
The man limitation of the system is its inability to meet the requirement
of large flow rate of water, particularly for high output engines.
Forced circulation Cooling System
This system is added in a large number of Automobiles.
Here the flow of water from radiators to water jackets is by
convection assisted by a pump
Forced circulation Cooling System
Water or coolant is circulated with through jackets around the parts of
the engine to be cooled is kept in motion by a centrifugal pump which is
driven by the engine
The water is passed through the radiator where it is cooled by the
forward motion of the vehicle
A thermostat is used to control the water temperature required for
cooling
This system consists of 4 components
Radiator water pump
Fan thermostat
Basic Schematic Layout
Cab heat
exchanger
Heater Control Thermo-
stat
Fan Radiator
Engine Block &
Cylinder head
Water Jacket Water
Pump
Parts of Engine Cooling System
Cooling System Construction
Radiator
Cap
Top Hose Radiator
Thermostat Fan
Water
Engine Block Pump
& Water
Jacket
Cold Engine
When an engine is cold, the
thermostat is cold. Coolant flow
is through the bypass hose and
the water jackets. This allows the
engine to warm up evenly.
Warm Engine
The thermostat opens when
the engine warms up. This
allows coolant to circulate
through the radiator and
the water jackets.
Water jackets
Defined as the open space within in the cylinder block and
cylinder head where coolant flows
Water jackets are designed to allow coolant flow to the right
spots flow so that maximum cooling can be obtained
Water Pump
The purpose
Is to circulate the water through the cooling system
Located on the front part of the engine
In most of the vehicles it is driven by a belt is attached to the crankshaft
As the crankshaft turns the fan belt turns
Cooling system
The water pump provides circulation of the engine coolant
(antifreeze) through the cooling system: it pushes the coolant
through the passages (water jackets) in the engine cylinder block
and cylinder head and then out into the radiator. The hot coolant
passes through the radiator where it cools down and then returns
back to the engine.
Centrifugal pump is the most used:it is a rotodynamic pump
that uses a rotating impeller to increase the pressure and flow rate
of a fluid. The fluid enters the pump impeller along or near to the
rotating axis and is accelerated by the impeller, flowing radially
outward or axially into a diffuser or volute chamber, from where it
exits into the downstream piping system.
A water pump is usually driven by the engine through the driving
belt and only sometimes by a timing belt. A water pump consists of
the housing with the shaft rotating on the bearing pressed inside.
At the outer side there is a pulley mounted on the shaft. At the
inner side there is a seal to keep the coolant from leaking out and
the impeller.
31
Cooling system
Main design characteristics
• Impeller diameter (∅ = 60 - 75 mm)
• Impeller height (h = 12 - 20 mm)
• Paddles number and design (z = 5 - 10)
• Axial and radial impeller clearance
• Drive ratio
npump
τ= = 1.3 - 1.6
nengine
32
Thermostat
One of the most important
parts of the cooling system
Purpose
Is to keep the engine coolant at
most efficient temperature
The thermostat is used to bring
the coolant temperature up to
operating as quickly as
possible
It is designed to sense the
temperature of the coolant
Thermostat
Cooling system
Target - In internal combustion engines a thermostat is used to maintain the engine at its
optimum operating temperature by regulating the flow of coolant to the external air cooled
radiator. It must balance the heat rejected from the engine to the coolant and the heat rejected
from the radiator to the ambient in any operating vehicle mode.
This type of thermostat operates mechanically: it makes use of a wax pellet inside a sealed
chamber. The wax is solid at low temperatures but as the engine heats up the wax melts and
expands. The sealed chamber has an expansion provision that operates a rod which opens a
valve when the operating temperature is exceeded. The operating temperature is fixed, but is
determined by the specific composition of the wax, so thermostats of this type are available to
maintain different temperatures, typically in the range of 70 to 90°C. Modern engines run hot,
that is, over 80°C, in order to run more efficiently and to reduce the emission of pollutants.
Most thermostats have a small bypass hole to vent any gas that might get into the system, e.g.,
air introduced during coolant replacement, which also allows a small flow of coolant past the
thermostat when it is closed. This bypass flow ensures that the thermostat experiences the
temperature change in the coolant as the engine heats up; without it a stagnant region of
coolant around the thermostat could shield it from temperature changes in the coolant adjacent
to the combustion chambers and cylinder bores.
Wax thermostatic elements permit the transforming of thermal energy into mechanical energy.
Their working principle is based on the large increase in the thermal expansion of waxes when
they pass from the solid to the liquid state
35
Radiator
Purpose
Is to allow fresh air to reduce the temperature of the coolant
As the coolant passes through the tubes air is forced
around the tube
This causes a transfer of heat from the hot coolant to the
cooler air. This is called Heat exchanged
In this case, heat is exchanged from the liquid coolant to
air. This is called a liquid-to air heat exchanger
Radiator
Coolant flows through the air fins
The fins and tubes are cooled core
Radiator Parts
Radiator Hose
Purpose
Transport coolant from engine to radiator and back
Radiator pressure cap
Pressure caps are designed to
Increase the pressure on the cooing system
Reduce cavitations
Protecting the radiator hose
Prevent or reduce surging
It is important to put pressure on the cooling system.
Radiator pressure caps are typically near 15 psi
As the pressure increases the boiling point of the coolant
also increases (about 3 degrees for each 1 psi increase
Pressure Cap
Pressure cap
Pressure cap
Expansion tank
Expansion tank
Fan
Electric Fan Relay
Coolant Temperature Indicator
Coolant Temperature Indicator
Types of Coolant
Coolant
Coolant
Coolant
Anti-freeze
IAT: inorganic additive technology
OAT: organic acid technology
HOAT: hybrid organic acid technology
Extended and conventional anti-freezes cannot be
mixed
EG: ethylene glycol
PG: propylene glycol
Anti-freeze
Maximum concentration: 67% anti-freeze
Minimum concentration: 50% for corrosion
prevention
Pure anti-freeze has higher viscosity and does not
flow well
Does not transfer heat well
