Design Calculation of Cooling System
(Radiator) for 1HD-T Diesel Engine
Ma May Mie Thet
Abstract— Internal combustion engines are equipped with
cooling system because of the high temperature generating
during operation. The coolant picks up heat and carries it to
the radiator. Air passing through the radiator carried way the
excess heat, which prevents engine overheating. Almost 30 to
35 percent of the total heat supplied by the fuel is removed by
this cooling system. To get an engine with good mechanical
efficiency, and to prevent engine overheating, the engine
block and head must be supplied with the proper cooling
system. The dimensions of the engine are 94 mm bore and 100
mm stroke. It produces maximum rated output power of 122
kW (163 HP) at 2000 rpm. In this thesis, depth of radiator,
water flow rate, fan speed and fan horsepower are calculated
in detail. This cooling system absorbs 25% of the heat
produced by the engine. The cooling system is designed to
absorb and dissipate this heat to the air stream flowing
through the radiator and over the engine.
Keywords— cooling system, radiator, engine overheating,
diesel engine, fan.
I. INTRODUCTION
I N internal combustion engine, about one-third of the heat
energy developed by the burning fuel is converted into
power; about a third is wasted and goes out the exhaust
unused. Cooling system concerned with disposing of the other
third of the heat. As the last part of the charge to burn is in
contact with the wall of the combustion space during the
burning period, a high cylinder wall or cylinder head
temperature will reduce the delay period and may cause
knocking.
Part of the heat developed during combustion flows
from the gases to the cylinder walls, rising their temperature.
If the wall temperature is allowed to rise above a certain limit,
about 149◦C, the oil that lubricates the piston begins to
evaporate rapidly, and both piston and cylinder may to injure.
At the same time high local temperatures in certain parts of
the engine, e.g., cylinder head and piston may cause excessive
stress and cracking of engine parts. In engines hot spots in the
May Mie Thet is with the Mandalay Technological University, Mandalay,
Myanmar ( corresponding author to provide phone: 095-2-88702; fax: 095-2-
88702; e-mail: miemiethett@gmail.com)
combustion space may cause pre-ignition. Almost 35 percent
of the total heat supplied by the fuel is removed by the cooling
system. The cooling system of diesel engine is liquid cooled
system. In this system, the coolant is circulated by the water
pump, and the thermostat controls the temperature. The
thermostat is closed when the engine is cold, allowing coolant
to circulate only in the engine block, bypassing the thermostat
and radiator. This allows the engine to warm up faster and
uniformly so that “hot spots” are eliminated. When the
warming coolant reaches the thermostat, the thermostat will
begin to open and allow coolant to pass the radiator. The
hotter the coolant gets, the more the thermostat opens,
allowing more volume of water to pass the radiator. The
thermostat also controls the length of time that the coolant
remains the radiator so that the heat is dissipated effectively.
II. TYPES OF COOLING SYSTEMS
The cooling system keeps the engine at its most
efficient temperature at all speeds and operating conditions.
Burning fuel in the engine produces heat. Some of this heat
must be taken away before it damages engine parts. The
cooling system should be provided around the engine
overheating. It also brings the engine up to normal operating
temperature as quickly as possible. Engines cooling systems
are broadly divided into two types:
1. Direct or air cooling systems
2. Indirect or liquid cooling systems
The air cooling system is used in engines of two or
three wheelers, aero planes and small stationary engines. In
other applications, the liquid cooling system is used. Water is
generally used in liquid cooling systems, in which additives
are sometimes added. In the closed cooling system, the hot
water from the water jackets is cooled in a heat exchanger and
re-circulated. The heat exchanger can be divided into two
types:
1. Water-to-air type (radiator)
2. Water-to-water type
The radiator-type cooling system is used in
automotive and stationary installations. In this system, the heat
of water is transferred to air directly. The water to water type
heat exchanger system is used in marine and industrial diesel
engines.
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III. COOLING SYSTEM COMPONENTS
The essential components of the cooling system
shown in Figure 1 are; water jackets, water pumps, engine
fans, drive belts, electric fans, radiator, thermostat, coolant
bypass passage, and pressure cap.
Figure 1. Engine Water Cooling System
IV. DESIGN CONSIDERATION FOR THE
COOLING SYSTEM COMPONENTS
Vw = Q rad
c w Δt w ρ w
where, cw = specific heat of the water (coolant)
Δtw = drop in the water temperature in the radiator(HH·C)
ρw = density of water (coolant) (kg /m3)
Vw = the velocity of the water in the pump intake duct
(m /sec)
where, ΔPpath = resistance of the stream path
fbl = factor depending on the shape of the blades;
for flat blades
u = The value of the peripheral velocity (m/sec)
According to the direction of the coolant flow, there
are basically two types of radiators, namely
1. Down flow radiator
2. Cross flow radiator
Down flow radiator is the most common used. In this
type of radiator, coolant will introduce from upper hose of
radiator and flow through the tube by downward motion. The
down flow radiator is a heat exchanger with two sets of
passages. One set is for coolant and the other for outside air.
This arrangement allows the radiator to remove heat from the
engine coolant passing through it. The heat transfers from the
hot coolant to the cooler outside air that also passes through
the radiator. Then the coolant flows back through the water
jackets to pick up heat again. In a running engine, the coolant
circulates continuously between the water jackets and the
radiator.
The radiator consists essentially of an upper tank
(inlet), a lower tank (outlet) and a core as shown in Figure 2.
The upper tank in some design may contain a removable filter
mesh to avoid dust particles going in into the radiator while
filling water in the radiator. Between the two tanks is the core
or radiating element. The upper tank is connected to the water
outlets from the engine jacket by rubber hose, and the lower
tank is connected by another rubber hose to the jacket inlet
through the pump.
(1)

Vfan = Af Vair (2)

where,
Af = face area of the radiator (m2)
Vair = velocity of air stream (m/sec)
Vfan = velocity of centrifugal fans (m/sec)

The fan diameter can be determined

Af (3)
D bl = 2
π
If the peripheral velocity of the blades is known, the fan speed Figure 2. Down-Flow Tube-and-Fin Radiator
is
60u (4) The design of a radiator is described by the
n fan = volumetric coefficient of compactness.
πD bl
A (6)
ϕ = total
rad
Vrad
The value of the peripheral velocity depending on the
head and a number of design parameters of the fan, where, φrad = the volumetric coefficient of compactness
Atotal = the total heat dissipation surface of the radiator
u = 0.89 fbl ΔPpath (5) in square meters.
The radiator volume,
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Vrad = A f l rad (7) Tube material - aluminum

Fin Spacing, Fp - 0.0787×25.4 mm
where, Vrad = the radiator volume (m3)
Fin thickness, b - 0.004 ×25.4 mm
A f = face area of the radiator (m2)
l rad = radiator depth (m); in motor vehicle
(1) The Amount of Heat Received by the Cooling Water
radiators (60~130) mm
The design amount of heat received by the cooling water is;
Qw = qw HL Gf (8)
Where, Qw= the amount of heat received by the cooling
V. DESIGN PROCEDURE FOR RADIATOR
water (J/hr)
The design procedure of Radiator for Diesel engine is
HL = lower heating value of fuel (J/kg)
as follow:
Gf = consumption of fuel (kg/hr)

(2) Amount of Heat Dissipated by the Radiator Surface

To allow for reduction of the heat transfer
coefficient a as result of clogging of the radiator face and of
scale deposits on the internal surfaces of the tubes, and for
deviations of the data used in the calculations from actual
conditions, the design amount of the heat is increased by 10
percent, and
Q rad = 1.1Q w (9)
where, Qrad = the amount of heat dissipated by the radiator
(J/hr)

(3) The Heat Dissipation Surface Area of the Radiator

The relationship between the design amount of heat
Qrad and the heat dissipation surface Atotal of the radiator is
expressed by the formula,
Q rad
Atotal = (10)
C h Δ t w.a
where,Atotal = heat dissipation surface area of the radiator(m2)
Ch = heat transfer coefficient

The temperature is equal to the difference between

the mean temperature of the cooling water and the air passing
through the radiator
Δ t wa = t wm - tam (11)
t +
t w.m = w.out w.int (12)
2
t a.m = t a.out + t a.in (13)
2
where, t w.out and t w.in = temperature of the water at the
radiator inlet and outlet
t a.out and t a.in = temperature of the air at the
radiator inlet and outlet
Figure 3. Design Procedure for Radiator
The mean temperature of the water is
The specification data for Radiator:
Water inlet temperature, Tin,w - 82.22 º C t w.m = t w.out - Δ t w (14)
Air inlet temperature, Tin,air - 37.78º C 2
Air outlet temperature, Tout, air - 46.11 º C The temperature of the air at the radiator inlet
Tube outside diameter, Do - 9 mm t a.in = t amb + Δ t f (15)
Tube thickness, t - 1 mm where, t amb = ambient temperature
Tube length, L - 0.55m Δ t f = amount heated air when it passes through the
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shutters or the oil cooler installed before the This 1 HD-T diesel engine output power is 163 hp
cooling system radiator. (122 kW). Water cooling systems usually permit better
Δ t w = water temperature drop in the radiator temperature control than is possible in air-cooled engines.
The temperature of the air at the radiator outlet when heated Cooling system efficiency is usually rated by the difference in
in the radiator by Δ t ais temperature between the water and the surrounding air. The
radiator design is to transfer the water’s heat energy to air.
t a..out = t a..in + Δ t a (16)
2 Power absorbed by the pump for water circulation is
considerable and this affects the power output of the engine.
(4) Total Number of Tube in the Radiator Although the radiator design of 1 HD-T diesel engine were
Inlet face area required, Af = Qrad (17) developed, there are still many works to enhance this radiator.
Q The radiator should have run for various coolant flow rate but
= radiator length × radiator height in this radiator, the coolant flow rate was mainly depends on
Total number of tube in radiator, design amount of heat release rate and remained constant for
N = NT x N l (18) all simulations.
NT = (radiator length) / (transverse pitch) Therefore, the emphasis in this paper is to present
where, N = total number of tube in radiator the operation and design calculations of radiator for four
NT = number of tube in the transverse plane wheel drive systems. And also to produce the various types of
Nl = number of tube in the longitudinal plane,3 Myanmar made modern car for national strategy of industrial
ST = 2XT = transverse pitch zones and to save the out flow of foreign currencies.
= 0.436 × 0.0254 = 0.0107 m
SL = 2XL= longitudinal pitch
ACKOWLEDGEMENT
(5) Mass Flow Rate of Cooling Water The author would like to say that the guidance and
The mass flow rate of cooling water is; teaching of teachers during undergraduate course could give
Qrad her good knowledge for learning the Master of Engineering
mow = (19) Course at M.T.U. The author is deeply thankful to her parents,
Δt w × Cp, w
brother and sisters for their support and encouragement to
where, m·w = mass flow rate of cooling water, kg/sec attain her attention without any trouble. The author is
Δ t w = drop in water temperature in the radiator dedicated her gratitude to all her teachers who gave their
(7 ~ 8K) knowledge from childhood until now and to all of her friends
Cp,w = pecific heat capacity of water ( J/kg.K) who helped her.

REFERENCES
VI. RESULT DATA OF RADIATOR [1] Wiliam H.Crouse. 1975. Automotive Mechanics. Seventh
Table 1. Result Data of Radiator Edition. Mc Graw-Hill Book Company, New York.
Result
Existing Dimensions [2] U Sein Win. 2003. Internal Combustion Engine Part I
No. Description Dimensions
for Radiator and II.
for Radiator
1. Radiator Depth, Lrad 0.0762 m 0.0752 m
[3] Stockel, Martin W. 1969. Auto Mechanies. How and Why
of the Design Construction and Operation of Automotive
2. Radiator height, h 0.559 m 0.542 m
Units (Second Edition) The Goodheart- Willcox Co.,INC
3. Radiator length, L 0.584 m 0.545 m
[4] William H. Crouse and Donald L. Anglin. 1994.
4. Number of tube in 3 tube 3 tube
Automotive Engine. Eigh Edition. International Edition,
longitudinal plane, N1 Mc Graw-Hill Book Company, New York.
5. Number of tube 53 tube 49 tube [5] Frank P. Incropera and David P. DEWitt, 1998,
in transverse plane, NT Fundamental of Heat and Mass Transfer (4th Edition),
6. Total number of tube 169 tube 159 tube John Wiley & Sons, Inc.
in Radiator, N
7. Tube outside diameter, 8.9 ×10-3 m 9×10-3 m
Do
8. Tube inside diameter, Di 6.9 ×10-3 m 7×10-3 m
9. The equipment diameter 0.0112 m 0.0111 m
of fin, Deq

VII. CONCLUSION