Flowmaster V7 for
Automotive Applications

Passenger Cars - Commercial Vehicles - Off Highway - Motorcycles
Requirements Simulation Products Airside Air Conditioning Cooling Exhaust Fuel Lubrication

Cooling Systems

Thermal Management is a significant challenge in the design of modern vehicles and a well designed cooling system is vital in overcoming this challenge. Designing and optimising for packaging space restrictions, powertrain architecture variations and thermal loads is essential.

The Cooling Systems Modelling packages from Flowmaster enable you to model your cooling system and optimise its design before building the real thing, whether you vary the design parameters of the thermostat to ensure a constant temperature in the cooling system or resize key components to packaging constrains.

Modelling Cooling systems in Flowmaster can allow you to evaluate the following:

  • The impact of components for different suppliers on the overall cooling system
  • The effects of different operating conditions; warm-up cycles in winter
  • The sizing of the expansion tank or de-gas bottle and its effects on performance

Click on image to enlarge
Click on image to enlarge


  • Model heat transfer effects for both Steady State and Transient flow conditions using a wide range of heat transfer options
  • Examine system pressures, flow rates and temperatures
  • Geometric Heat Exchanger Modelling (available with Advanced Heat Exchanger Module )
  • Model with a wide range of standard and cooling specific components
  • Learn with cooling specific tutorials and help
  • Co-simulate with other industry tools such as ANSYS Fluent, STAR-CD and MATLAB®/Simulink®
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  • Design and optimise cooling systems to underhood sizing and packaging constraints
  • Investigate if coolant temperature oscillations occur and whether they affect passenger comfort or engine emissions
  • Accelerate your validation process by simply importing test data directly into the cooling system model

Case Studies

Caterpillar and Argonne National Laboratory meet sound regulations with the help of Flowmaster, at a fraction of the cost and time

With confidence in their Flowmaster simulation results, Caterpillar engineers can now simulate many different configurations and scenarios of enclosed engine compartment cooling systems before the testing phase of the design cycle. This means that with the aid of Flowmaster, engineers can now bring the best possible design for off-road machines that meet sound regulations all at the fraction of cost and time.

Cummins design industrial diesel engine cooling systems with Flowmaster

Before designing their new cooling system, it was imperative to have a certain comfort level in the accuracy of the results generated by Flowmaster.  This comfort level was attained by making use of a Flowmaster flow balanced model of the QSK19 gas engine, adding in thermal components and validating against test cell results.  (The QSK19 gas engine base model was flow balanced, or validated against test flow data and adjusted to match the test results.)  The simulation results were within 5% of testing.  Now having a high confidence level of Flowmaster as an accurate simulation tool, Cummins proceeded to use Flowmaster to design a new cooling system.

DaimlerChrysler AG meet stringent performance specifications of their new eight-cylinder diesel engine cooling system using Flowmaster

One month before a major project milestone, final testing on test rigs and in-vehicle were underway when DaimlerChrysler's cooling engineers experienced an unexpected challenge with a specific area of the cooling system: the exhaust-reconducting radiator. Flowmaster's Germany based team were called in for modelling and methodologies advice to help evaluate the technical options available.