Published Paper Details:

The growing demand for enhanced thermal comfort, energy efficiency, and compact design in modern vehicles necessitates the optimization of Heating, Ventilation, and Air Conditioning (HVAC) systems. HVAC duct design plays a pivotal role in determining airflow distribution, noise levels, and overall system efficiency. This project focuses on the optimization of HVAC duct systems in passenger vehicles through the application of Computational Fluid Dynamics (CFD) analysis. The primary objective is to reduce pressure losses, improve airflow uniformity, and enhance thermal comfort without compromising the packaging constraints of the vehicle interior. The study begins with a baseline evaluation of a conventional HVAC duct design using CFD simulations to identify inefficiencies such as turbulence zones, high-pressure drops, and flow separation areas. Using this baseline as a reference, various design modifications are proposed, including changes in duct geometry, bends, splitter locations, and vent positions. Each modified design is analysed through CFD tools to assess parameters such as velocity distribution, static pressure, turbulence intensity, and flow uniformity. Optimization techniques, including parametric analysis and design of experiments (DOE), are employed to systematically refine the duct design. The final optimized design demonstrates a significant reduction in pressure drop (by 6 pascal), improved flow uniformity at passenger outlets, and enhanced overall HVAC performance. Additionally, noise generation due to turbulent flow is minimized, contributing to improved cabin comfort. The project validates the effectiveness of CFD as a powerful tool in the automotive HVAC system design process. The results highlight the potential for computational analysis to accelerate development cycles, reduce physical prototyping costs, and deliver better-performing systems. This study serves as a framework for future research and development of energy-efficient and ergonomically optimized vehicle HVAC systems.