Optimal Experiment Design for the Identification of the Interfacial Heat Transfer Coefficient in Sand Casting

The interfacial heat transfer coefficient(IHTC)is one of the main input parameters required by casting simulation software.It plays an important role in the accurate modeling of the solidification process.However,its value is not easily identifiable by means of experimental methods requiring temperature measurements during the solidification process itself.For these reasons,an optimal experiment design was performed in this study to determine the optimal position for the temperature measurement and the optimal thickness of the rectangular cast iron part.This parameter was identified using an inverse technique.In particular,two different algorithms were used:Levenberg Marquard(LM)and Monte Carlo(MC).A numerical model of the solidification process was associated with the optimization algorithm.The temperature was measured at different positions from the mould/metal interface at d=0 mm(mould/metal interface),30 mm,60 mm and 90 mm.the thicknesses of the cast part were:L1=40 mm,60 mm and 80 mm.A comparative study on the IHTC identification was then carried out by varying the initial value of the IHTC between 500 Wm^(-2)K^(-1) and 1050 Wm^(-2)K^(-1).Results showed that the MC algorithm used for estimating the IHTC gives the best results,and the optimal position was at d=30 mm,the position closest to the mould/metal interface,for the lowest thickness L1=40 mm.

Optimal design of the separate type heat pipe heat exchanger

Separate type heat pipe heat exchangers are often used for large-scale heat exchanging. The arrangement of such a heat exchanger conveniently allows heat input to and output from the heat exchanger at remote locations. The traditional method of designing an ordinary HPHE (heat pipe heat exchanger) is commonly applied in the separate type exchanger design, but the calculations have to be carried out separately, which makes it very complicated. In this work, the ε-NTU (effectiveness-Number of Transfer Units) method was applied for optimization analysis of single- or multi-level separate type heat pipe heat exchangers. An optimizing formula for single-level separate type heat pipe heat exchangers was obtained. The optimizing principles of effec- tiveness-NTU and heat transfer rate by the equal distribution method for multi-level separate type heat pipe heat exchanger are presented. The design of separate type heat pipe heat exchangers by the optimizing method is more convenient and faster than by the traditional method.

Conceptual design and heat transfer performance of a flat-tile water-cooled divertor target

The divertor target components for the Chinese fusion engineering test reactor(CFETR)and the future experimental advanced superconducting tokamak(EAST)need to remove a heat flux of up to20 MW m-2.In view of such a high heat flux removal requirement,this study proposes a conceptual design for a flat-tile divertor target based on explosive welding and brazing technology.Rectangular water-cooled channels with a special thermal transfer structure(TTS)are designed in the heat sink to improve the flat-tile divertor target’s heat transfer performance(HTP).The parametric design and optimization methods are applied to study the influence of the TTS variation parameters,including height(H),width(W*),thickness(T),and spacing(L),on the HTP.The research results show that the flat-tile divertor target’s HTP is sensitive to the TTS parameter changes,and the sensitivity is T>L>W*>H.The HTP first increases and then decreases with the increase of T,L,and W*and gradually increases with the increase of H.The optimal design parameters are as follows:H=5.5 mm,W*=25.8 mm,T=2.2 mm,and L=9.7 mm.The HTP of the optimized flat-tile divertor target at different flow speeds and tungsten tile thicknesses is studied using the numerical simulation method.A flat-tile divertor mock-up is developed according to the optimized parameters.In addition,high heat flux(HHF)tests are performed on an electron beam facility to further investigate the mock-up HTP.The numerical simulation calculation results show that the optimized flat-tile divertor target has great potential for handling the steady-state heat load of 20 MW m-2under the tungsten tile thickness<5 mm and the flow speed7 m s^(-1).The heat transfer efficiency of the flat-tile divertor target with rectangular cooling channels improves by13%and30%compared to that of the flat-tile divertor target with circular cooling channels and the ITER-like monoblock,respectively.The HHF tests indicate that the flat-tile divertor mock-up can successfully withstand 1000 cycles of20 MW m-2of heat load without visible deformation,damage,and HTP degradation.The surface temperature of the flat-tile divertor mock-up at the 1000th cycle is only930℃.The flat-tile divertor target’s HTP is greatly improved by the parametric design and optimization method,and is better than the ITER-like monoblock and the flat-tile mock-up for the WEST divertor.This conceptual design is currently being applied to the engineering design of the CFETR and EAST flat-tile divertors.

Optimization of DC Resistance Divider Up to 1200 kV Using Thermal and Electric Field Analysis

Self-heating and electric field distribution are the primary factors affecting the accuracy of the Ultra High Voltage Direct Current(UHVDC)resistive divider.Reducing the internal temperature rise of the voltage divider caused by self-heating,reducing the maximum electric field strength of the voltage divider,and uniform electric field distribution can effectively improve the UHVDC resistive divider’s accuracy.In this paper,thermal analysis and electric field distribution optimization design of 1200 kV UHVDC resistive divider are carried out:(1)Using the proposed iterative algorithm,the heat dissipation and temperature distribution of the high voltage DC resistive divider are studied,and the influence of the ambient temperature and the power of the divider on the temperature of the insulating medium of the divider is analyzed;(2)Established the finite element models of 1200 kV and 2×600 kV DC resistive dividers,analyzed the influence of the size of the grading ring and the installation position on the maximum electric field strength of the voltage divider,and calculated the impact of the shielding resistor layer on the vicinity of the measuring resistor layer.The research indicates that:(1)The temperature of the insulating medium is linearly related to the horsepower of the voltage divider and the ambient temperature;(2)After the optimized design of the electric field,the maximum electric field strength of the 1200 kV DC resistive divider is reduced to 1471 V/mm,which is about 24% lower than that of the unoptimized design;(3)Installing the shielding resistor layer can significantly improve the electric field near the measuring resistor layer.This paper has an important reference function for improving the accuracy of the UHVDC resistive divider.

Laser Surface Hardening of Tool Steels—Experimental and Numerical Analysis

This research work is focused on both experimental and numerical analysis of laser surface hardening of AISI M2 high speed tool steel. Experimental analysis aims at clarifying effect of different laser processing parameters on properties and performance of laser surface treated specimens. Numerical analysis is concerned with analytical approaches that provide efficient tools for estimation of surface temperature, surface hardness and hardened depth as a function of laser surface hardening parameters. Results indicated that optimization of laser processing parameters including laser power, laser spot size and processing speed combination is of considerable importance for achieving maximum surface hardness and deepest hardened zone. In this concern, higher laser power, larger spot size and lower processing speed are more efficient. Hardened zone with 1.25 mm depth and 996 HV surface hardness was obtained using 1800 W laser power, 4 mm laser spot size and 0.5 m/min laser processing speed. The obtained maximum hardness of laser surface treated specimen is 23% higher than that of conventionally heat treated specimen. This in turn has resulted in 30% increase in wear resistance of laser surface treated specimen. Numerical analysis has been carried out for calculation of temperature gradient and cooling rate based on Ashby and Easterling equations. Then, surface hardness and hardened depth have been numerically estimated based on available Design-Expert software. Numerical results indicated that cooling rate of laser surface treated specimen is high enough to be beyond the nose of the CCT diagram of the used steel that in turn resulted in a hard/martensitic structure. Numerically estimated values of surface temperature, surface hardness and hardened depth as a function of laser processing parameters are in a good agreement with experimental results. Laser processing charts indicating expected values of surface temperature, surface hardness and hardened depth as a function of different wider range of laser processing parameters are proposed.

Numerical Investigations on Fluid Flow and Heat Transfer Characteristics of an Ultra-Thin Heat Pipe with Separated Wick Structures

Thermal and fluid-flow characteristics were numerically analyzed for ultra-thin heat pipes.Many studies have been conducted for ultra-thin heat pipes with a centered wick structure,but this study focused on separated wick structures to increase the evaporation/condensation surface areas within the heat pipe and to reduce the concentration of heat flux within the wick structure.A mathematical heat-pipe model was made in the threedimensional coordinate system,and the model consisted of three regions:a vapor channel,liquid-wick,and container wall regions.The conservation equations for mass,momentum,and energy were solved numerically with boundary conditions by using a code developed by one of the authors.The numerical results with the separated wick structures were compared with those with the centered,which confirmed the effectiveness of the separation of the wick structure.However,the effectiveness of the separation was affected by the position of the separated wick structure.A simple equation was presented to determine the optimum position of the separated wick structures.Numerical analyses were also conducted when the width of the heat pipe was increased with the cooled section,which clarified that the increase in the cooled-section width with the addition of wick structures wasmore effective than the increase in the cooled-section length.A 44%reduction in the total temperature difference of the heat pipe was obtained under the present numerical conditions.Furthermore,a comparison wasmade between experimental results and numerical results.

面向金属泡沫散热器设计的自然对流拓扑优化

针对传统方块型金属泡沫散热器散热效率不高,难以满足高功率电子器件散热需求的问题,发展了基于格子Boltzmann和水平集方法的三维拓扑优化方法。首先,采用格子Boltzmann方法求解多孔介质内的流动和传热过程;然后,采用伴随格子Boltzmann方法计算梯度;最后,根据反应-扩散方程更新水平集函数。通过对底部放置发热元件方腔的自然对流过程开展拓扑优化,得到特征格拉晓夫数为2.4×10^(2)~1.2×10^(5)的4种优化散热器结构,定量评估了散热器的强化换热性能并分析相关机理。研究结果表明:随着格拉晓夫数的增大,散热主导机制由热传导转变为热对流,优化结构由伸展的树枝状向收缩的花朵状结构转变,以留出更多空间使得流动涡旋充分发展;与传统的金属泡沫方块结构和开槽的金属泡沫块结构相比,所提优化结构表现出优异的散热性能,其分支结构和中空结构能够优化方腔内的流动,从而将散热效率提升了29.7%以上,表明了所提拓扑优化方法的有效性。研究工作可为新型金属泡沫散热器的设计提供理论指导。

拟除虫菊酯农药降解菌HP-S-01培养基的筛选及优化

通过比较高氏合成1号培养基、查彼氏培养基、马铃薯葡萄糖培养基、燕麦片培养基和理查德培养基等5种培养基对拟除虫菊酯农药降解菌Streptomyces sp.HP-S-01生长的影响,确定了高氏合成1号培养基为菌株生长最适宜的培养基。以高氏合成1号培养基为基础培养基,采用中心组分旋转设计法(RRCD)和响应曲面法(RSM),优化了培养基关键组分中可溶性淀粉、硝酸钾和磷酸氢二钾的组成,以降解率为主要衡量指标,最佳配方包括可溶性淀粉25.9549g/L、硝酸钾1.9975g/L和磷酸氢二钾0.9505g/L,最终优化出的培养基处理1 d后对50 mg/L高效氯氰菊酯的降解率达到99.61%,与期望降解率99.92%相一致,比优化前84.10%提高了15.51%。

基于Kriging模型的螺旋波纹管流动换热特性及结构优化

在螺旋管式换热器的基础上结合波纹结构,设计出一种新型的螺旋波纹管换热器.通过数值计算研究了不同波纹深度和波纹节距对其流动换热的影响.以数值计算结果训练Kriging模型,训练后的Kriging模型可预测大量不同螺旋波纹结构特征样本的流动换热特性.通过筛选摩擦系数较低且换热效率较高的结构参数以实现螺旋波纹管换热特性优化.结果表明,波纹结构产生的流速突变和螺旋结构产生的二次流提高了换热效率和流动阻力.通过与数值计算结果的对比,Kriging模型预测换热特性具有较高的效率和精度.在所选定的参数范围内,当波纹深度、波纹节距、螺旋中径、螺旋节距分别为1.32,27.99,86.49,57.85 mm时,螺旋波纹管具有较低的摩擦系数和较高的换热效率.

响应面分析翅片参数对含内热源封闭腔内对流-辐射耦合传热特性的影响

为研究内置翅片参数对含内热源封闭腔内自然对流-辐射耦合传热的影响,在是否考虑内壁面辐射效应的基础上,对不同翅片单参数下腔内传热能力进行了数值分析对比,并就翅片多参数交互作用对腔内对流-辐射耦合传热效果的影响进行了响应面分析。结果表明:一定强度的壁面辐射有利于改善热源表面和冷壁面的对流换热效果。壁面辐射使得翅片附近的冷壁面局部Nu数波动程度有所增强,冷壁面平均Nu数相比无翅片工况最高提升了16.74%;无论是否考虑辐射,翅片单参数变化,翅片长度l对热源表面平均Nu数的影响最为显著,最优翅片单参数均依次为:θ=120°、l=0.02H、a=0.75H,考虑辐射对应的热源表面平均Nu数提升率η更高,分别为10.15%、11.03%、10.48%;引入响应面优化法,分析得出翅片长度与安装高度的交互作用对热源表面平均Nu数影响最显著,腔内对流-辐射耦合传热效率最高的翅片参数组合为:θ=117.94°,l=0.023H,a=0.734H,此时,热源表面平均Nu数为26.50,相比无翅片工况提升了13.15%。所得翅片参数影响规律及多目标优化结果反映各因素交互作用显著度的同时,也为改善工业装置封闭空间内发热元件对流冷却效果提供了理论指导。

多层套管式换热器的传热过程分析计算

在传统套管式换热器的基础上,为了增加换热面积、扩大流量和强化传热,提出一种新型结构的多层套管式换热器,且对其结构、原理和特点进行概述;其次对这种换热器的传热过程进行分析简化,建立物理模型,确定传热过程的关系式;结合工程实际应用,选择冷热流体、结构参数和运行工况进行液-液和气-液换热计算,确定换热器的基本结构和应用场合。最后通过正交试验的方法,对套管表面加装直肋和螺旋翅片进一步结构优化,得到最佳的翅片的厚度、高度和间距,同时比较了在最优结构参数下换热器与传统管壳式换热器的传热特性,可供工程应用提供参考。

燃气电厂烟气余热回收吸收塔设计优化与实验研究

为减少碳排放、有效提高能源利用效率,对某燃气热电厂烟气系统进行了余热回收改进设计。采用填料喷淋技术对原有的余热喷淋塔进行结构优化设计,将吸收换热塔优化为填料塔,有效强化换热性能。结果表明,优化后烟气余热回收吸收塔不仅消除了原系统水泵气蚀、振动和噪声的问题,还解决了换热塔“失水”的问题。在输入燃气量不变、输出电力不变的前提下,输出热量有效提高10%以上,脱硝效率稳定达到70%以上,NO_(x)最低浓度可稳定维持<10 mg/m^(3)。与常规供热方案相比,本余热回收方案年回收烟气热量2.789万GJ,并带来了可观的经济与环境效益,每个采暖季减少天然气使用量约86.70万标方,减少CO_(2)排量约1610 t/年。

航空发动机旋转盘腔内部流动换热特性研究进展综述

The rotating disk cavity is an important part of the cooling-air system of the aero engine,and it has obviously significance to study the internal flow and heat transfer characteristics of the disc cavity,which will be helpful to improve the efficiency of the aero engine.This paper summarizes the existing research results of domestic and overseas.The present work considers the test methods and calculation methods of the flow and heat transfer characteristics of the rotating disc cavity of the aircraft engine.It points out that,the main factors which affect the heat transfer characteristics are the disc chamber speed,the intake volume,the design of the disc cavity pre-rotation/despin structure,and the type of disc cavity system.The influence of these factors on the characteristics of flow heat transfer is summarized.Based on these factors,the disc cavity structure can be optimized and designed,which provides suggestions for reducing the weight of the turbine,improving the thrust-to-weight ratio of the aero engine,and improving the cooling efficiency.

大功率光伏逆变器IGBT模块的散热分析和优化设计

针对光伏逆变器小型化、轻量化、高功率化发展带来的散热设计难题,设计了一种有效的强制风冷散热优化方案。首选,通过风量计算选定了合适风机;其次,使用代价函数对散热器质量和散热效果进行了双目标优化;最后,通过响应面优化得到了最优散热设计方案。结果表明:散热器温度和IGBT芯片结温均远低于标准要求,且保留裕量10℃以上。该结果为类似逆变器产品的散热优化设计提供了思路和参考。

乙烯装置冷箱工艺技术提升措施

冷箱是乙烯装置的重要过程设备之一,对质量可靠性的要求很高,其运行的好坏直接影响着乙烯装置的长周期安全稳定运行。冷箱的工艺设计和传热设计非常关键,需要给予足够的重视。通过调研国内乙烯装置冷箱在操作和运行中所遇到的问题,归纳冷箱在工程设计中面临的难点和要点,总结冷箱工艺设计技术,并提出了工艺优化的各项建议措施,对乙烯装置中深冷分离单元的工艺设计和操作具有一定指导意义。

换热器传热性能优化设计及实验验证研究

换热器是工业生产中广泛使用的重要设备之一。它的传热性能直接影响着生产效率和能源利用率。基于换热器传热机理,对换热器传热性能优化设计进行了系统研究,并通过实验对优化设计方案进行了验证。研究表明,优化设计后的换热器传热系数提高,压降减小,整体传热性能得到了显著提升,可为换热器设计提供新思路,对提高工业生产效率和节能减排具有重要意义。

基于一维传热模型的洗碗机能耗仿真和优化

在家电领域,降低碳排放、提高产品能效水平是近些年的发展趋势。洗碗机产品由于洗涤温度和烘干餐具的要求,加热方式以电加热为主,能耗值较高。基于某平台电热洗碗机产品的工作特性,建立一维热仿真模型并描述洗涤周期中的传热过程和能量分布,总能耗预测误差小于4%,并从餐具吸热量的角度提出表征餐具洗净程度的特征参数——洗净因子。并进一步根据NLPQL优化算法对洗碗机能耗进行优化设计,研究发现在保证相同洗净水平时其能耗可降低6%,研究结论对洗碗机产品设计中平衡能耗和洗净效率具有参考价值。

Optimal design analysis of a tubular heat exchanger network with extended surfaces using multi-objective constructal optimization

The present work aims to investigate the influence of extended surfaces(fins)on the multi-objective optimization of a tubular heat exchanger network(THEN).An increase in the heat transfer area using various extended surfaces(fins)to enhance the performance of the heat exchanger was used while considering the effectiveness and total heat transfer area as two objective functions.In addition to the simulation of simple fins,a new set of fins,called constructal fins,was designed based on the constructal theory.Tubular heat exchanger network design parameters were chosen as optimization variables,and optimization results were achieved in such a way as to enhance the effectiveness and decrease the total heat transfer area.The results show the importance of constructal fins in improving the objective functions of heat exchangers.For instance,the simple fins case enhances the effectiveness by up to 5.3%compared to that without fins(usual heat exchanger)while using constructal fins,in addition to the 7%increment of effectiveness,reduces the total heat transfer area by 9.47%.In order to optimize the heat exchanger,the heat transfer rate and cold fluid temperature must increase,and at the same time,the hot exiting fluid temperature should decrease at the same constant total heat transfer area,which is higher in the constructal fins case.Finally,optimized design variables were studied for different cases,and the effects of various fins were reported.

Evaporation Heat Transfer Characteristics from a Sintered Powder Wick Structure Sandwiched between Two Solid Walls

An ultra-thin flattened heat pipe has been developed with a centered wick structure.This structure is essential to make the heat pipe thinner.However,the centered wick structure reduces the evaporation and condensation surface areas of the wick structure because it is sandwiched between heat pipe walls.In this study,because detailed discussion has not been made,heat transfer experiments were conducted for the wick structure sandwiched between two solid walls.This study focused on the evaporation heat transfer characteristics from the sandwiched wick structure.The experiments were conducted with three wick structures,that is,strip-shaped sintered copper powders with thicknesses of 0.5,1.0,and 1.5 mm.Water was used as working fluid.The capillary pumping performance,that is,the liquid lifting velocities of the three wick structures were the same.The experimental results of the three wick structures were compared regarding the relation between the evaporation heat transfer rate and the superheat of the working fluid.The heat transfer experiments were also conducted when one of the solid walls was removed from the wick structure.It was confirmed that even if the wick structure was sandwiched between the solid walls,sufficient evaporation of the working fluid occurred from the thin sides of the wick structure.

流体拓扑优化的方法及应用综述

流体拓扑优化是一项突破性技术,在航空航天、汽车、电子芯片等领域均有广泛的应用前景,然而其所设计出的复杂结构难以通过传统制造技术加工成型等因素制约了它的推广应用。增材制造(3D打印)技术的发展为进一步拓展流体拓扑优化的应用和研究提供了有效途径,对实现相关工业装备的结构轻量化、动力学优化、安全性优化以及性能提升,落实国家“节能降耗、碳达峰碳中和”战略具有重要意义。借助文献计量工具VOSviewer对Web of Science数据库中流体拓扑优化相关文献进行了梳理和总结,全面系统阐述了流体拓扑优化的理论体系、求解方法、优化方法以及工程应用,并对相关问题进行了探讨。首先,与固体拓扑优化相比,流体拓扑优化涉及领域更广、流态特征更多样、数学模型更复杂,因而求解更困难、计算时间更长、计算资源需求更大,这是制约流体拓扑优化工程应用的主要因素。其次,较系统阐述了流体拓扑优化的3个环节和关键技术:拓扑设计变量表述方法、CFD模型及求解方法、拓扑优化模型及求解方法,并分析了现有技术的特点和应用场景,同时,对流体拓扑优化的电子芯片热沉、飞机汽车、换热器等几个应用场景进行了简述。最后,对流体拓扑优化的发展趋势进行了预测和总结,建议进一步加大湍流、共轭传热、流-固-热耦合、流-固-热-质耦合等方面的多学科拓扑优化研究;拓展基于多目标函数的拓扑优化研究;进一步加强与人工智能的深度结合,开发更加稳健成熟的智能CFD求解器、智能优化求解器以及智能流体拓扑优化软件。