Engine Thermal Shock Testing Prediction Through Coolant and Lubricant Cycling in Dymola

This document explores the development and validation of a high-fidelity multi-domain thermal shock testing model using Dymola and Modelica to simulate engine coolant and lubricant thermal cycling during accelerated durability testing of internal combustion engines.

The research integrates detailed thermal representations of engine heat rejection, coolant conditioning systems, lubricant circuits, heat exchangers, chillers, pumps, and control systems to recreate rapid thermal cycling scenarios that induce thermo-mechanical stress and component fatigue. Using validated physical rig models and experimental test data, the study demonstrates how predictive simulation can accurately replicate heating and cooling transients, optimise thermal shock test control strategies, identify undesirable system behaviours such as pressure spikes and oscillations, and reduce engineering effort prior to physical testing. The work highlights the value of virtualised thermal testing environments for improving engine durability analysis, control system calibration, and thermal management system development.