modeFRONTIER for Virtual Design and Optimization of Compact Heat Exchangers

The main purpose of this study is the development of an innovative methodology for Heat Exchangers (HE) design to replace the conventional design procedures. The new procedure is based on the definition of a software package managed by modeFRONTIER, a multi-objective optimization software produced by ESTECO, able to create HE virtual models by targeting several objectives, like HE performance, optimal use of material, HE minimal weight and size and optimal manufacturability. The proposed methodology consists first in the definition of a workflow for the automatic CFD simulation of a parametric model of a periodic HE cellular element. This is followed by the definition of a Response Surface (meta-model) covering all the possible range of parameters' combination, the definition of a “bridge”, e.g. low-fidelity - standard or macroscopic - models to extend the behavior of the liquid and air HE cellular elements to a real scale HE, and an optimization process to obtain the optimal HE design for any proposed application and requirements. The versatility of the methodology, thanks to the modularity of modeFRONTIER platform, offers the possibility of a large scenario of applications for Fluid Power systems, where Heat Exchangers (for both fixed and mobile applications) are used to cool down the oil or any other working fluid. In this work the main aspects covering the background of the project, the proposed methodology and the expected benefits will be introduced. In addition, validation of the CFD models with experimental data available in the literature will be illustrated, as well as an example of “bridge” optimization with the use of experimental correlations available in the literature.