Intercooler modelling programs

[RONA]

Plazmaman must do some modelling/testing as he rates the intercoolers to a given HP application. Could be random marketing figures but you'd hope you have some data to back up a good for 1200hp claim etc. Funnily enough his website lists a 600x300x76mm China Core to 500hp.

[JustenGT8]

The PWR cores are too narrow so not keen to use one of their core. The K&J cores look to be the best out there and can be supplied by ARE...be nice to source one direct if possible if anyone can hook me up with a connection?

Plazmadude would be close on the 76mm china core as that what i originally had and it looked to be starting to choke around 280rwkw? The 100mm core still seems good at 400rwkw but as i said...heavy!!

[trdee]

Plazmaman must do some modelling/testing as he rates the intercoolers to a given HP application. Could be random marketing figures but you'd hope you have some data to back up a good for 1200hp claim etc. Funnily enough his website lists a 600x300x76mm China Core to 500hp.

There wouldnt be any in depth calculation behind those. Just rules of thumb from finding that x size cooler generally flows x amount of power. But with this kind of stuff that's all you can do really.

[RONA]

^^^^ Nope some testing has to of been done as some smaller cores have higher rating. They also have various cores all the same size with different ratings depending on the core/end tank design etc.

[trdee]

i never said testing wasnt done. but in depth calculations wouldnt have. its not hard to run different types of cores in varying sizes back to back to see trends...

[mattysshop]

error post

[JustenGT8]

Thanks Matty

Well i've found a compromise core....same dimensions as my current core but uses the profiled tube and fin cores of my original new option. Price is good too so no stress if it's just as good Theoretically it should flow more as the x-sectional area is 120% better and being 600mm long the heat shedding has to be pretty decent.

Lighter too but doesn't allow the major intake plumbing changes i'd like to do. I'll keep it in the fallback draw for now

I sent a query to ARE in a small novel so they are probably still reading it....hopefully they can provide some guidance and maybe even a reasonably priced product.

[brett_celicacoupe]

without going into too much details. here are some points of relevance.

air flow through past the core is equally as important as airflow through the core since Q_inside core = Q_past core.

turbulent flow is better for heat transfer. turbulent flow also means higher pressure drop. this means you need to get a compromise between the 2. i think this would make the design objective such that air flow through the tubes is high enough to achieve turbulence but not to cause excessive restriction.

you could actually calculate the approximate speed of the air within the core tubes. ie you know the dimensions of each 'tube' (and thus cross section) and the number of tubes. you also know your maximum air mass flow rate (convert to volume). once you know these figures, reynolds number can be easily computed to determine the flow type.


I think the heat transfer side of the calculations are too complex. instead, its better to look at the flow capacity of the intercooler. im unsure on what range of reynolds number is optimal.

[brett_celicacoupe]

here is an article that may be useful. i only skimmed through it but there may be something of relevance


http://www.toymods.org.au/forums/att...1&d=1295739601

[JustenGT8]

Update.

I sent an email off to ARE and had a good follow up chat with Richard (?) about my ideas and what they could do for me. he ran the numbers thru their model (i didn't ask many questions on the model as that's their's and part of how they make their money) and the vertical core of the dimensions i can fit gets a big tick and would work well. The length is enough for cooling with their core and pressure drop should reduce significantly....WI can only help so rec was to keep that.

Only a 73mm core required too so weight savings are decent.

Downside cost is substantial. Guestimate $1800 which would no doubt blow out to $2K, plus there's some plumbing mods required and likely a shorter rad than the current one to allow a central outlet. On top of the engine build etc etc etc....my cheap (relatively) proj could turn into a massive money pit and i'd have been better off just buying an Evo in the 1st place? Not necessarily the point, but puts the dollars in perspective.

I can do it myself i think for alot less but won't be as well designed i suspect....if i can get 80% of the gains then probably good enough so going to see a couple of guys that have done fab work for me in the past and see what we can come up with.

[oldcorollas]

are the ARE cores significantly better in terms of tube entry design etc? size isn't the only thing, but 2K is certainly spendy, esp in light of cheaper options..
will they just supply core?

[Supra967]

not cheap but they put a lot of effort into their cooling. I think their water cores are fairly good from the reading.

[JustenGT8]

Their work looks top shelf....worth the coin? I guess it is to those that pay

Cores ain't cores but what i have or can get should stack up in flow terms at least, and what they lose in eff i will make up with WI. My main concern was the 'short' flow path was way too short and i hadn't a hope.....ARE say i'm OK in that regard (just) so WI should get me across the line no worries.

ARE were VERY impressed with the results i get with WI so reinforces this is a must have mod for FI to me

[Supra967]

How much was your WI to hook up? Also what length is your short path? Did he give any indication of how much temp drop you'd get from the cooler?

Its great that ARE put so much info up publically. I think they actually test their coolers rather than just sell lots of them. I was too scared to ask for a price though

[JustenGT8]

My WI was a bitsa kit i put together from stuff i had lying around.

He talked more in general terms, but that 320mm flow path got me in the right range on their modelling program and from experience he was happy with that as well. Reckons i should gain some boost as well as the pressure drop across the shorter core could improve by as much as a psi based on other China cores they have upgraded from.

I have asked for a price on just the core....it will still be exxy me thinks.