COOLING

SYSTEM
 Introductio
n
 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
Introductio
n
 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.
 Introductio
n
 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

 Introductio
n
 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
Introductio
n 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
where:

Q f = heat introduced into the engine through the fuel combustion

work equivalent heat at the engine shaft
h
Q =
u
heat realeased to the engine cooling system
Qw =
Q g = heat rejected to the exhaust gases

Qi = lost heat for radiance

 Introductio
n
 Variation of Gas Temperature Piston Temperature
Distribution
 Introductio

nHeat 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
 Introductio

nCylinder 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 Water
Jacket 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

n pump
= 1.3 - 1.6
 nengine

32
Thermosta
t
 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
Thermosta
t
 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
Fa
n
Electric Fan
Relay
Coolant Temperature
Indicator
Coolant Temperature
Indicator
Types of
Coolant
Coolan
t
Coolan
t
Coolan
t
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