Development of Simulation and Optimization Tool for Heat Exchanger Design

The performance of high-performance engines, particularly in two-wheelers, often faces challenges due to inadequate cooling systems. Traditional heat exchangers, such as the cross-flow type, struggle to provide optimal heat dissipation, especially in engines exceeding 200cc. This research explores the use of Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), to fabricate microchannel heat exchangers with flat and curved face geometries. The study aims to evaluate the thermal performance, heat transfer efficiency, and air resistance of these AM-produced heat exchangers compared to traditional designs. Through thermal analysis, Computational Fluid Dynamics (CFD) simulations, and experimental setups, the research identifies significant improvements in heat dissipation and cooling efficiency when using AM technology. The results reveal that the curved face design outperforms the flat face configuration in terms of thermal performance and pressure characteristics. Additionally, material properties such as ABS, PLA, and PETG were assessed, showing that ABS provided the best balance of durability and thermal performance. This study concludes that AM-based microchannel heat exchangers are a viable solution to overcome the limitations of conventional designs, offering enhanced performance and greater efficiency in modern cooling systems.