Engines, Motors, and

Mobility
[ME F317]
BITS Pilani Dr. Saket Verma
Department of Mechanical Enginerring
Pilani Campus
 BITS Pilani
Pilani Campus

Lecture No.: 19
Thermal management in I.C.
Engines
Engine cooling system

A system, which controls the engine temperature, is known as a

cooling system.

 The high working temperatures of the internal combustion engine

which are the cause of its high efficiency are at the same time a
source of great practical difficulty in construction and operation.
 The maximum temperature during combustion is approximately the
melting point of platinum and the temperature even of the exhaust
gases is above that of aluminium.
 It is thus essential that heat be abstracted at a sufficient rate to
prevent a dangerous temperature being reached
 Nevertheless, it must always be borne in mind that such abstraction
of heat is a direct thermodynamic loss

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Engine cooling system

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NECESSITY OF COOLING
SYSTEM
• The temperature of the burning gases in the engine cylinder reaches up
to 1500 to 2000°C, which is above the melting point of the material of
the cylinder body and head of the engine. (Platinum, a metal which
has one of the highest melting points, melts at 1750 °C, iron at
1530°C and aluminium at 657°C.) Therefore, if the heat is not
dissipated, it would result in the failure of the cylinder material.
• Due to very high temperatures, the film of the lubricating oil will
get oxidized, thus producing carbon deposits on the surface. This will
result in piston seizure.
• Due to overheating, large temperature differences may lead to a
distortion of the engine components due to the thermal stresses
set up. This makes it necessary for, the temperature variation to be
kept to a minimum.
• Higher temperatures also lower the volumetric efficiency of the engine.
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REQUIREMENTS OF
EFFICIENT COOLING SYSTEM
1. It must be capable of removing optimum amount of the heat
generated in the combustion chamber. Too much removal of
heat lowers the thermal efficiency of the engine.
2. It should remove heat at a fast rate when the engine is hot.
During the starting of the engine, the cooling should be very
slow so that the different working parts reach their operating
temperatures in a short time. – Responsive system

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ENGINE HEAT TRANSFER
CONCEPTS

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AREAS of Heat Transfer from
Engine

Areas where heat transfer is important–

Intake system: manifold, port, valves– In-cylinder: cylinder head,
piston, valves, liner– Exhaust system: valves, port, manifold, exhaust
pipe– Coolant system: head, block, radiator– Oil system: head, piston,
crank, oil cooler, sump

•Information of interest from designing perspective–

Heat transfer per unit time (rate)– Heat transfer per cycle (often
normalized by fuel heating value)– Variation with time and location of
heat flux (heat transfer rate per unit area)

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CYLINDER TEMPERATURE
DISTRIBUTION
Temperature distribution and heat flow across the combustion
chamber wall

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Combustion Chamber Heat
Transfer

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Radiative Heat Transfer

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Overall Average Heat Transfer Coefficient

A classic correlation for the overall average engine heat transfer coefficient,
ℎo, between the cylinder and the coolant is that of Taylor (1985).

In terms of the mass flow rate into the engine per unit piston area, the
Reynolds number is defined

The overall heat flux 𝑞′′ from an engine cylinder to the coolant is calculated
using the piston area 𝐴 = 𝐴p = 1∕4 𝜋 𝑏2 as a reference area:

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Numerical problem

Q: Compute the overall average heat transfer coefficient ℎo and heat flux 𝑞′′ for a
single-cylinder engine with a 0.1 m bore and stroke, average combustion gas
temperature of 1000 K, coolant temperature of 350 K, and fuel--airflow rate of 2 ×
10-3 kg/s. Assume 𝑘 = 0.06 W/(m K) and 𝜇 = 20 × 10-6 Ns/m2

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Instantaneous Cylinder Average Heat
Transfer Coefficient
• The instantaneous cylinder average heat transfer coefficient, ℎg(𝜃),
between the combustion gas and cylinder wall is a function of crank angle,
and is an input to the finite heat release model.
• Two instantaneous cylinder average heat transfer correlations that have
been widely used are the Annand and the Woschni correlations.
• The Annand (1963) correlation was developed from cylinder head
thermocouple measurements of instantaneous heat flux. It uses a
constant characteristic velocity, the mean piston speed 𝑈̄ p, and a
constant characteristic length, the cylinder diameter 𝑏. The Annand
correlation is:

• The Woschni correlation (1967) was developed using a heat balance

analysis for each stroke of a direct injection diesel engine and uses a
variable characteristic gas velocity to account for the increased gas
velocity induced by combustion. The Woschni correlation is

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Engine heat balance

SI Engine CI Engine
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Engine heat balance in a
modern SI engine

Energy balance for the SI gasoline Energy balance for the SI gasoline
engine at 2000 rpm –BMEP = 0.2 engine at 3500 rpm –BMEP = 0.5
MPa. MPa.

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Engine heat balance in a
modern CI engine

Energy balance for the Diesel engine at Energy balance for the Diesel engine at
1500 rpm – BMEP =0.3 MPa. 2300 rpm – BMEP =0.8 MPa.

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Fig.: Engine heat balance during start of the engine.

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Engine Heat Transfer: Impact

• Efficiency and Power: Heat transfer in the inlet decrease volumetric

efficiency. In the cylinder, heat losses to the wall is a loss of
availability.
•Exhaust temperature: Heat losses to exhaust influence the
turbocharger performance. In- cylinder and exhaust system heat
transfer has impact on catalyst light up.
•Friction: Heat transfer governs liner, piston/ ring, and oil
temperatures. It also affects piston and bore distortion. All of these
effects influence friction. Thermal loading determined fan, oil and
water cooler capacities and pumping power.
•Component design: The operating temperatures of critical engine
components affects their durability; e.g. via mechanical stress, lubricant
behavior

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Engine Heat Transfer: Impact

• Mixture preparation in SI engines: Heat transfer to the fuel

significantly affect fuel evaporation and cold start calibration.

•Cold start of diesel engines: The compression ratio of diesel engines

are often governed by cold start requirement

•SI engine octane requirement: Heat transfer influences inlet mixture

temperature, chamber, cylinder head, liner, piston and valve
temperatures, and therefore end-gas temperatures, which affect knock.
Heat transfer also affects build up of in-cylinder deposit which affects
knock.

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Types of cooling systems in
vehicles
AIR COOLING SYSTEM LIQUID COOLING SYSTEM

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AIR COOLING SYSTEM

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Air Cooling System in Engine

In the air cooling system, the heat is dissipated directly to the air
after being conducted through the cylinder walls.
Air cooling systems have fins and flanges on the outer surfaces of
the cylinders.
The heads serve to increase the area exposed to the cooling air,
and so raise the rate of cooling.
The amount of heat dissipated based on the following factors.
1. The surface area of metal into contact with air.
2. The rate of air flow.
3. Temperature difference between the heated surface and the air.
4. The conductivity of the metal.

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Comparison
Advantages
• Lighter in weight
• No topping up the cooling
system
• No leaks to guard against.
• Anti-freeze not required.
• Engine warms-up faster than
with water-cooled design.
• This system can be work in
cold climates where water may
freeze.
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Disadvantages
• Less efficient cooling system,
because of the coefficient of
heat transfer for air is less than
that for water.
• It is not easy to maintain even
cool around the cylinder, the
cylinder deformation can
occur.
Comparison

 Air-cooling is mostly tractors of less horsepower,

motorcycles, scooters, small cars and small aircraft
engines where the forward motion of the machine
gives good velocity to cool the engine.
 Air-cooling is also provided in some small industrial
engines. In this system, individual cylinders are
generally employed to provide ample cooling area by
providing fins.

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LIQUID COOLING SYSTEM

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Liquid cooling system

This cooling system has four types of systems:

(i) Direct or non-return system,
(ii) Thermo-Syphone system, Obsolete systems
(iii) Hopper system and
(iv) Pump/forced circulation system.

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Force Circulation Water
Cooling System
• It makes use of a centrifugal pump to circulate the
coolant/water throughout the water jackets and radiator
• The water flows from the lower portion of the radiator to the
water jacket of the engine through the centrifugal pump.
• After the circulation water comes back to the radiator, it loses
its heat by the process of radiation. This system is employed in
cars, trucks, tractors, etc

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Parts of a liquid cooling
system
The main parts in the water-cooling system are:
(i) water pump,
(ii) radiator and pressure cap,
(iii) fan,
(iv)fan belt
(v) water jacket,
(vi) thermostat valve,
(vii) temperature gauge and
(viii) hose pipes.

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Parts of a liquid cooling
system

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Liquid Cooling System

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 Water pump

• A water pump is a simple device that will keep the coolant

moving as long as the engine is running.
• It is usually mounted on the front of the engine and turns
whenever the engine is running.
• This is a centrifugal type pump. It is usually driven by means
of a belt.

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Coolant Pump

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Water Pump

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 Radiator

• The purpose of the radiator is to cool down the water received

from the engine.
• A better name for a radiator would be a convector because it
warms the air passing over it.
• The radiator consists of three main parts: (i) upper tank, (ii)
lower tank and (iii) tubes.
• Hot water from the upper tank, which comes from the engine,
flows downwards through the tubes.
• The heat contained in the hot water is conducted to the copper
fins provided around the tubes.

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Radiator

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Radiator

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Radiator Pressure Cap
• when water is boiled in a closed radiator under high pressure, the
boiling temperature of water increases.
• The higher water temperature gives more efficient engine
performance and affords additional protection under high altitude
and tropical conditions for long hard driving periods.
• Therefore, a pressure-type radiator cap is used with the forced
circulation cooling system. The cap is fitted on the radiator neck
with an air tight seal.
• The pressure-release valve is set to open at a pressure between 4 and
13 psi.
• Any increase in pressure is released by the pressure release valve to
the atmosphere.
• An expansion tank is provided. On cooling, the vapours will
condense and a partial vacuum will be created.

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Radiator Pressure Cap

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Radiator Pressure Cap

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 Radiator Fan

• The engine fan, which maintains the flow of air through the
radiator, is mounted on the water pump pulley on older
systems.
• Most cooling fans are now electric. These are more efficient
because they only work when needed.
• The forward motion of the car also helps the air movement
through the radiator.
• It is usually mounted between the radiator and the engine so
that the air can easily get to the radiator.

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Radiator Fans

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Fan & Belts

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Water Jackets

Passageways through which water circulates through the

block.

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Water Jackets

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 Thermostat

• It is a kind of check valve which opens and closes with the

effect of temperature.
• It is fitted in the water outlet of the engine. During the warm-
up period, the thermostat is closed and the water pump
circulates the water only throughout the cylinder block and
cylinder head.
• When the normal operating temperature is reached, the
thermostat valve opens and allows hot water to flow towards
the radiator.
• Standard thermostats are designed to start opening at 70 to
75°C and they fully open at 82°C.

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Thermostat Valve

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Thermostat Valve

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Thermostat Valve

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 Radiator Hose

• There are several rubber hoses that make up the plumbing to

connect the components of the cooling system.
• The main hoses are called the upper and lower radiator hoses.
• Materials :EPDM(Ethylene propylene diene monomer), Nitrile
rubber & Neoprene rubber

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Radiator Hose

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 Coolant

• The coolant in today's vehicles is a mixture of ethylene glycol

(antifreeze) and water.
• Different percentage solutions are used for different
conditions. A mixture with about 33% of antifreeze is often
acceptable, but more may be required in very cold conditions.
• A hydrometer measures the relative density of the liquid,
which changes depending on the amount of antifreeze.

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 Heating system

• Heat from the engine can be used to increase the temperature

of the car interior.
• This is achieved by use of a heat exchanger, often called the
heater matrix.
• Due to the action of the thermostat in the engine cooling
system, the coolant temperature remains nearly constant.
• The air being passed over the heater matrix is therefore heated
to a set level.
• On most modern vehicles the amount of heat reaching the
inside of the car is controlled by blending.

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Heating system

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Heater Core

Additional heat
exchanger can be
provided, where some of
the coolant can be
recirculated to achieve
heating requirements.

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Water jackets

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https://www.youtube.com/watch?v=y5p31F_dVJU

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