Optimizing Heat Transfer Efficiency: CFD Analysis of Microchannel Designs for Two-Wheeler Radiators

Heat exchangers are pivotal in engineering applications for transferring thermal energy between two fluids across a separation wall, especially within Microchannel Heat Exchangers (MCHXs). These devices, known for their compactness and lightweight design, offer exceptional heat transfer capabilities. Yet, a significant challenge arises in the misdistribution of two-phase fluids within these systems, particularly at the inlet header of evaporators, where this misdistribution affects the uniform flow into the microchannel tubes. Leveraging recent advancements in Computational Fluid Dynamics (CFD) for multiphase flow, this study embarks on a detailed exploration of the flow behavior inside MCHX headers, employing CFD modeling to scrutinize the heat transfer parameters of flat face versus curved face MCHX designs. Our methodology involves comprehensive CFD simulations to investigate the thermal dynamics within these exchangers, focusing on how design variations impact heat transfer efficiency. The analysis reveals a notable advantage of the curved face MCHXs: a higher local heat transfer coefficient. This enhancement is attributed to improved fluid mixing and an increase in surface interaction within the curved face design. Through detailed CFD analysis, this paper not only addresses the challenge of fluid misdistribution but also illuminates the potential of curved face MCHXs to enhance heat exchanger performance in practical applications significantly.