CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

Studying Cu Alloy Corrosion Products in Cooling Liquid

The effect of cooling liquid used for heat exchangers on the Cu alloy corrosion products has been examined using potential-time measurements under applied current condition (anodizing), potentiodynamic polarization, X-ray diffraction (XRD) and infrared spectroscopy (IR) The corrosion products formed on the Cu alloy surface during anodizing, are Cu2O, Cu2(OH)3Cl, and Cu2S. NaCl is detected in the corrosion products. The film formation depends on the applied current and the shift of potential to nobler direction indicates its formation progress.

Research on Performance Optimization of Liquid Cooling and Composite Phase Change Material Coupling Cooling Thermal Management System for Vehicle Power Battery

The serpentine tube liquid cooling and composite PCM coupled cooling thermal management system is designed for 18650 cylindrical power batteries,with the maximum temperature and temperature difference of the power pack within the optimal temperature operating range as the target.The initial analysis of the battery pack at a 5C discharge rate,the influence of the single cell to cooling tube distance,the number of cooling tubes,inlet coolant temperature,the coolant flow rate,and other factors on the heat dissipation performance of the battery pack,initially determined a reasonable value for each design parameter.A control strategy is used to regulate the inlet flow rate and coolant temperature of the liquid cooling system in order to make full use of the latent heat of the composite PCM and reduce the pump’s energy consumption.The simulation results show that the maximum battery pack temperature of 309.8 K and the temperature difference of 4.6 K between individual cells with the control strategy are in the optimal temperature operating range of the power battery,and the utilization rate of the composite PCM is up to 90%.

Thermal Simulation for Two-Phase Liquid Cooling 3D-ICs

This work presents an algorithm for simulating more accurate temperature distribution in two-phase liquid cooling for three-dimensional integrated circuits than the state of-the-art methods by utilizing local multi-linear interpolation techniques on heat transfer coefficients between the microchannel and silicon substrate, and considering the interdependence between the thermal conductivity of silicon and temperature values. The experimental results show that the maximum and average errors are only 9.7% and 6.7% compared with the measurements, respectively.

Research on Thermal Management Control Strategy of Electric Vehicle Liquid Cooling Battery Pack

Due to the risk of thermal runaway in the charging and discharging process of a soft packed lithium battery pack for electric vehicles,a stamping channel liquid cooling plate cooling system is designed,and then the heat dissipation problem of the battery pack is solved through reasonable thermal management control strategy.Using computational fluid dynamics simulation software star-CCM+,the thermal management control strategy is optimized through simulation technology,and the temperature field distribution of battery pack is obtained.Finally,an experimental platform is built,combined with experiments,the effectiveness of the thermal management control strategy of the cooling system is verified.The results show that when the battery pack is in the environment of 25℃,the maximum temperature of the cooling system can be lower than 40℃,the maximum temperature difference between all single batteries is within 5℃,and the maximum temperature difference between inlet and outlet coolant is 3℃,which can meet the heat dissipation requirements of the battery pack and prevent out of control heat generation.

Design and analysis of an advanced thermal management system for the solar close observations and proximity experiments spacecraft

In this paper,the mission and the thermal environment of the Solar Close Observations and Proximity Experiments(SCOPE)spacecraft are analyzed,and an advanced thermal management system(ATMS)is designed for it.The relationship and functions of the integrated database,the intelligent thermal control system and the efficient liquid cooling system in the ATMS are elaborated upon.For the complex thermal field regulation system and extreme space thermal environment,a modular simulation and thermal field planning method are proposed,and the feasibility of the planning algorithm is verified by numerical simulation.A solar array liquid cooling system is developed,and the system simulation results indicate that the temperatures of the solar arrays meet the requirements as the spacecraft flies by perihelion and aphelion.The advanced thermal management study supports the development of the SCOPE program and provides a reference for the thermal management in other deep-space exploration programs.

Immersed liquid cooling Nd:YAG slab laser oscillator

An immersed liquid cooling slab laser is demonstrated with deionized water as the coolant and a Nd:YAG slab as the gain medium.Using waveguides,a highly uniform pump beam distribution is achieved,and the flow velocity distribution is also optimized in the channels of the gain module(GM).At various flow velocities,the convective heat transfer coefficient(CHTC)is obtained.Experimentally,a maximum output power of 434 W is obtained with an optical–optical efficiency of 27.1%and a slope efficiency of 36.6%.To the best of our knowledge,it is the highest output power of an immersed liquid cooling laser oscillator with a single Nd:YAG slab.

Performance analysis and optimization of free cooling strategies for a liquid-cooled data center

The increasing power density of IT electronics and the enormous energy consumption of data centers lead to the urgent demand for efficient cooling technology.Due to its efficiency and safety,liquid-cooled heat sink technology may gradually replace air-cooled technology over time.With the ambient or higher water supply temperature,the liquid-cooled technology shortens the operating time of the chiller and improves its coefficient of performance,while the pump power consumption may increase for satisfying the constant cooling capacity.Therefore,it is significant to study the optimal water supply temperature to achieve energy-efficient operation of data centers.A virtual 30.1 kW data center is considered as the case,the liquid-cooled system is constructed with a combination of innovative manifold microchannel heat sink with oblique fins and indirect evaporative cooling technology to minimize energy consumption.A hybrid thermal management model integrating the heat dissipation model and the power consumption model is established by TRNSYS and FLUENT software.To the highest chip-safe operating temperature premise,the energy performance is analyzed under various water supply temperatures in Guangzhou.The result shows that only 21.5-hour mechanical cooling is needed with the 30℃server inlet temperature throughout the year.And the minimized power consumption occurs with the constant 29℃server inlet temperature.Moreover,the temperature adaptive control strategy(TACS)is adopted to test the cooling system power consumption under different regulation frequencies,and the by-week TACS can achieve another 11.5%energy saving than the minimum power consumption of the constant temperature control strategy.

Experimental study on the mechanism of flow blockage formation in fast reactor

Various sources of solid particles might exist in the coolant flow of a liquid metal cooled fast reactor(e.g.,through chemical interaction between the coolant and impurities,air,or water,through corrosion of structural materials,or from damaged/molten fuel).Such particles may cause flow blockage accidents in a fuel assembly,resulting in a reduction in coolant flow,which potentially causes a local temperature rise in the fuel cladding,cladding failure,and fuel melt.To understand the blockage formation mechanism,in this study,a series of simulated experiments was conducted by releasing different solid particles from a release device into a reducer pipe using gravity.Through detailed analyses,the influence of various experimental parameters(e.g.,particle diameter,capacity,shape,and static friction coefficient,and the diameter and height of the particle release nozzle)on the blockage characteristics(i.e.,blockage probability and position)was examined.Under the current range of experimental conditions,the blockage was significantly influenced by the aforementioned parameters.The ratio between the particle diameter and outlet size of the reducer pipe might be one of the determining factors governing the occurrence of blockage.Specifically,increasing the ratio enhanced blockage(i.e.,larger probability and higher position within the reducer pipe).Increasing the particle size,particle capacity,particle static friction coefficient,and particle release nozzle diameter led to a rise in the blockage probability;however,increasing the particle release nozzle height had a downward influence on the blockage probability.Finally,blockage was more likely to occur in non-spherical particles case than that of spherical particles.This study provides a large experimental database to promote an understanding of the flow blockage mechanism and improve the validation process of fast reactor safety analysis codes.

Operation Optimization of Liquid Cooling Systems in Data Centers by the Heat Current Method and Artificial Neural Network

Liquid cooling systems in data centers have been attracting more attentions due to its better cooling capability and less energy consumption. In order to propose an effective optimization method for the operation of indirect liquid cooling systems, this paper first constructs an experiment platform and applies the heat current method to build the global heat transfer constraints of the whole system. Particularly, the thermal conductance of each heat exchanger under different working conditions is predicted by the Artificial Neural Networks(ANN) trained by the historical data. On this basis, combining the heat transfer and fluid flow constraints together with the Lagrange multiplier method builds the optimization model with the objective of minimum pumping power consumption(PPC), solving which by the solution strategy designed obtains the optimal frequencies of the variable frequency pumps(VFPs). Operating with the optimal and other feasible operating conditions validates the optimization model. Meanwhile, the experiments with variable heat loads and flow resistances provide some guidelines for the optimal system operation. For instance, to address heat load increase of a branch, it needs to increase the frequencies of the VFPs, not only the corresponding hot loop but also the whole cold loop.

Numerical investigation of transcritical liquid film cooling in a methane/oxygen rocket engine

Transcritical film cooling was investigated by numerical study in a methane cooled methane/oxygen rocket engine.The respective time-averaged Navier-Stokes equations have been solved for the compressible steady three-dimensional(3-D) flow.The flow field computations were performed using the semi-implicit method for pressure linked equation(SIMPLE) algorithm on several blocks of nonuniform collocated grid.The calculation was conducted over a pressure range of 202 650.0 Pa to 1.2×107 Pa and a temperature range of 120.0 K to 3 568.0 K.Twenty-nine different cases were simulated to calculate the impact of different factors.The results show that mass flow rate,length,diameter,number and diffused or convergence of film jet channel,injection angle and jet array arrangements have great impact on transcritical film cooling effectiveness.Furthermore,shape of the jet holes and jet and crossflow turbulence also affect the wall temperature distribution.Two rows of film arranged in different axial angles and staggered arrangement were proposed as new liquid film arrangement.Different radial angles have impact on the film cooling effectiveness in two row-jets cooled cases.The case of in-line and staggered arrangement are almost the same in the region before the second row of jets,but a staggered arrangement has a higher film cooling effectiveness from the second row of jets.

Experimental investigation on a novel liquid cooling device for a prismatic Li-ion battery module operating at high ambient temperature

A novel liquid cooling device for a prismatic LiFePO4 battery module was proposed and manufactured in this study in order to improve the thermal management performance of the battery module operating at high ambient temperature.A testing system was set up to experimentally measure temperatures in different locations of the battery module consisting of seven 60 Ah cells.Tests were conducted to investigate both the passive and active cooling performances of the proposed system at different ambient temperatures and discharging rates in regarding with the maximum temperature and difference between the maximum and minimum temperatures.The results clearly show that both the ambient temperature and discharging rate play important role on the maximum temperature of the battery module.Passive cooling cannot meet the cooling requirement of the battery module particularly at high ambient temperature of 40℃.In contrary,liquid cooling can successfully reduce the maximum temperature to the required temperature range of the battery module even in high temperature environment and relatively high discharging rate.The effect of water inlet temperature on the cooling performance was also experimentally studied.With the inlet temperature of 28℃,the active cooling device can reduce the maximum temperature of the battery module to about 34.8℃after discharging at 0.6℃for 1000 s.The temperature difference of only 3.8℃was also achieved which suggests a great uniform distribution of temperature in the battery module.

Numerical study of wave disturbance in liquid cooling film

Transient numerical simulations are carried out to investigate the liquid-gas interfacecharacteristics associated with liquid film cooling flows.A two-dimensional axisymmetricmulti-phase numerical model using finite volume formulation is developed.The model hasbeen validated against available experimental data for liquid-film cooling flows inside tubes.The model has been used to predict the interface characteristics for a variety of imposedparameters and momentum flux ratios under cold flow conditions wherein both the coolant andmainstream are maintained at the same temperature.Disturbance waves are observed at theliquid-gas interface for coolant flows above a critical value and after a finite distance from theinlet.The distance toward the wave inception point increased with the increase of momentumflux ratio.However,at higher momentum flux ratios,the properties of the disturbance wavesdid not vary significantly.The parameters related to the liquid-gas interface waves,namely,wave velocity,frequency,amplitude and wave length have been analyzed in detail.Analysisindicates that the liquid entrainment is due to the shearing of the disturbance wave crest.

Numerical simulation of axial liquid film cooling in rocket combustor

Numerical simulation has been done for liquid film cooling in liquid rocket combustor.Multiple species of axial Navier-Stokes equations have been solved for liquid-film / hot-gas flow field,and k-εequations have been used for compressible turbulent flow.The results of the model agree well with the results of software FLUENT.The results show that :(1) Liquid film can decrease the wall heat flux and temperature effectively,and the cold border area formed by the film covers the whole combustor and nozzle wall.(2) The turbulent viscosity is higher than the physical viscosity,and its biggest value is in the border area of the convergent area in nozzle.The effect of turbulent flow on the whole simulation field can not be ignored.(3) The mass fraction of kerosene at the film inlet is 1,but it decreases along the nozzle wall and achieves its lowest value at the outlet.However,the mass fraction of kerosene near the wall is the biggest at any axial location.

Flow and thermal modeling of liquid metal in expanded microchannel heat sink

Liquid metal-based microchannel heat sinks (MCHSs) suffer from the low heat capacity of coolant, resulting in an excessive temperature rise of coolant and heat sink when dealing with high-power heat dissipation. In this paper, it was found that expanded space at the top of fins could distribute the heat inside microchannels, reducing the temperature rise of coolant and heat sink. The orthogonal experiments revealed that expanding the top space of channels yielded similar temperature reductions to changing the channel width. The flow and thermal modeling of expanded microchannel heat sink (E-MCHS) were analyzed by both using the 3-dimensional (3D) numerical simulation and the 1-dimensional (1D) thermal resistance model. The fin efficiency of E-MCHS was derived to improve the accuracy of the 1D thermal resistance model. The heat conduction of liquid metal in Z direction and the heat convection between the top surface of fins and the liquid metal could reduce the total thermal resistance (Rt). The above process was effective for microchannels with low channel aspect ratio, low mean velocity (Um) or long heat sink length. The maximum thermal resistance reduction in the example of this paper reached 36.0%. The expanded space endowed the heat sink with lower pressure, which might further reduce the pumping power (P). This rule was feasible both when fins were truncated (h_(2) < 0, h_(2) is the height of expanded channel for E-MCHS) and when over plate was raised (h_(2) > 0).

Additive Manufacturing of Liquid-Cooled Ceramic Heat Sinks:An Experimental and Numerical Study

With recent advances in power electronic packaging technologies,liquid-cooled ceramic heat sinks have been considered as a promising solution for further improving the performance of power electronic devices.In this study,several aluminum oxide heat sinks were fabricated and tested using the digital light processing-based ad-ditive manufacturing method,to verify their practical performance.The results showed that the complex cooling structures inside the heat sinks can be completely formed and exhibited high surface quality.The experimental thermal and hydraulic performances of the heat sinks were consistent with the numerically modeled predictions.Furthermore,by exploiting the advantages of additive manufacturing,a direct manifold microchannel(MMC)configuration was designed to reduce the vertical flow of the traditional MMC configuration and achieve an im-proved cooling efficiency.At a constant volumetric flow rate of 1 L/min,the direct MMC configuration achieved a 19.8%reduction in pressure drop and an 11.8%reduction in thermal resistance,as well as a more uniform temperature distribution.

Liquid metal as energy transportation medium or coolant under harsh environment with temperature below zero centigrade

The current highly integrated electronics and energy systems are raising a growing demand for more sophisticated thermal management in harsh environments such as in space or some other cryogenic environment. Recently, it was found that room temperature liquid metals （RTLM） such as gallium or its alloys could significantly reduce the electronics temperature compared with the conventional coolant, like water, oil or more organic fluid. However, most of the works were focused on RTLM which may subject to freeze under low temperature. So far, a systematic interpretation on the preparation and thermal properties of liquid metals under low temperature （here defined as lower than O^C） has not yet been available and related applications in cryogenic field have been scarce. In this paper, to promote the research along this important direction and to overcome the deficiency of RTLM, a comprehensive evaluation was proposed on the concept of liquid metal with a low melting point below zero centigrade, such as mercury, alkali metal and more additional alloy candidates. With many unique virtues, such liquid metal coolants are expected to open a new technical frontier for heat transfer enhancement, especially in low temperature engineering. Some innovative ways for making low melting temperature liquid metal were outlined to provide a clear theoretical guideline and perform further experiments to discover new materials. Further, a few promising applied situations where low melting temperature liquid metals could play irreplaceableroles were detailed. Finally, some main factors for optimization of low temperature coolant were summarized. Overall, with their evident merits to meet various critical requirements in modem advanced energy and power industries, liquid metals with a low melting temperature below zero centigrade are expected to be the next- generation high-performance heat transfer medium in thermal managements, especially in harsh environment in space.

Measurements of heat transfer and pressure in a trailing edge cavity of a turbine blade

An experimental investigation is conducted to obtain the heat transfer and pressure drop data for an integral trailing edge cavity test section that simulates a novel turbine blade＇s internal cooling passage with bleed holes. Local heat transfer is measured on both the suction and pressure sides by a transient liquid crystal technique, while pressures at six positions are recorded by pressure calibrators. Moreover, flow characteristic and its effect on heat transfer are analyzed for conditions with or without bleed flow. The experimental results show that, in the cases with bleed flow, local heat transfer on the pressure side exceeds that on the suction side in the first and second channels. In the cases without bleed flow, in the first and third channels, local heat transfer on the suction side weakens whilst it increases significantly on the pressure side. For the second channel, non-bleed condition leads to a more balanced heat transfer distribution between the upstream and downstream channel. Besides, after the bleed holes are blocked, heat transfer in the first bend region on the suction side declines sharply, while the opposite phenomenon occurs for the second bend region on the pressure side. In both bleed and non-bleed cases, the total pressure of six measurement positions decreases continuously along the channel at the same Reynolds number and it promotes for higher Reynolds number. Among all the measurement points, under the same flow rate condition, the highest speed occurs at Position 5, which also shows the maximum difference between the total and static pressures. When the bleed holes are blocked, the total pressure at each measurement position appears to increase.