The aim of our project is Thermal Design, Optimization and Model Fabrication of a Test Bench Cross-Flow Heat Exchanger. In cross flow are dealing with compact heat exchanger. As radiator is the most widely used application of a compact cross-flow heat exchanger. So a radiator for an existing 84kW Deutz diesel engine (model BF4M1012EC) was designed. The construction of our design consists of tubes and fins as the normal radiator have. Design of our fin is of wavy-fin and rectangular tube is selected, because wavy fin and tube design is widely used and it has higher thermal efficiency. We have developed a code in EES (Engineering Equation Solver) which, by which we can design radiator for any engine according to the manufacturer requirement and simulate any geometric design and perform parametric analysis of the given specification. Our test bench has sensors for temperature and pressure measurement by which we have verified our theoretical and experimental result. This report consists of the interfacing of our variables to computer through data acquisition card. This gives us the wide range data processing. This report consists of thermal design and geometrical modeling of the specific radiator as mentioned above. We have developed the heat transfer model of the system starting form the Fourier’s Law and Newton law of cooling. Our main emphasis is in finding the convective heat transfer coefficient both in air side and tube side. For this we have taken help form the thesis of our project supervisor Liaquat Ali Khan. After finding the convective heat transfer coefficient we have to find the pressure drop in the tube and out the tube. There are also some calculation of pumping power and fan power.

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