Browse Topic: Heat transfer
To facilitate the development and application of bulb-flat titanium alloys in aerospace and automotive industries, this study selects TC4 as the research material and employs finite element simulation software to simulate the hot rolling process of TC4 bulb flat titanium. The temperature field, strain field, and metal flow velocity in each rolling pass are analyzed, and rolling experiments are conducted after optimizing the roll pass system. The results indicate that during the rolling process of TC4 bulb flat titanium, the head undergoes relatively smaller deformation, resulting in a slower temperature decrease, whereas the waist experiences greater deformation and a faster temperature drop. A significant temperature difference exists between the core and surface, which can be mitigated by appropriately increasing the roll temperature to reduce heat transfer. Prior to the K4 pass, the billet temperature drops to a level that may affect rolling performance, necessitating furnace reheating. Strain increases progressively with each rolling pass, with higher values observed at the waist compared to the head. A gradual strain transition occurs at the interface between the head and waist. Furthermore, the irregular design of the roll pass leads to a considerable difference in metal flow velocity between the upper and lower surfaces. During the K1 pass rolling, this imbalance can cause the guide guard to be displaced upward and result in roll wrapping. Without altering the roll diameter, shifting the entire roll pass system toward the side with higher metal flow velocity effectively reduces the linear velocity and prevents these issues, ensuring stable billet rolling. Rolling experiments successfully produced the final TC4 bulb flat titanium, thereby validating the feasibility of the optimized roll pass system and the rationality of the selected rolling parameters. It provides the possibility for its development and application in fields such as aircraft and automobiles.
This study prepares high-performance PI/VIP composite thermal insulation materials for buildings by integrating polyimide (PI) composite membranes and vacuum insulation panels (VIPs), and uses EnergyPlus to explore their impacts on building energy conservation, operating costs, and carbon emissions under different climates. Experimental results show the materials have low thermal conductivity, long service life, and excellent thermal insulation and flame-retardant properties due to their internal vacuum structure inhibiting heat transfer. Simulations in Jinan (tropical monsoon), Heilongjiang (cold temperate), and Shenzhen (subtropical humid) climates indicate that compared with traditional XPS and rock wool boards, buildings using PI/VIP composites achieve 21.3%, 34.7%, and 18.9% higher annual energy-saving efficiency respectively, with 27%-41% lower carbon emissions; the most significant effects in Heilongjiang highlight the material’s great promotion potential in severe cold areas.
In recent years, especially in high-performance spark-ignition engines, the thermal stress of pistons has gradually increased due to the implementation of various technologies, aimed at meeting emission reduction and specific power increase requirements. If the heat is not properly dissipated, cracking and plastic deformation of the material as well as formation of hot spots triggering pre-ignition in the combustion chamber mixture can occur. This last aspect is even more true considering innovative fuels such as hydrogen. To overcome these problems, one or more jets of oil are directed towards the piston under-crown region, impacting at high speed. This technique ensures immediate cooling and allows the engine performance to be increased without compromising the useful life. In order to optimize the oil jet effectiveness, 3D-CFD can be proficiently adopted. In this regard, the aim of this work is to define a robust numerical methodology able to simulate oil jet impingement and piston thermal field. In particular, a 3D-CFD Volume-of-Fluid (VoF) simulation is used to numerically assess the oil jet impact and provide a map of heat transfer coefficients, which, in turn, is adopted in a 3D-CHT model to estimate the piston thermal field. The proposed methodology is validated against experimental data on a high-performance engine piston. In particular, a pair of oil jets is investigated and the resulting heat transfer coefficient map is exploited to obtain the thermal field of the piston, which is finally compared to the available experimental temperature measurements. The results show that the predicted temperatures agree with the experimental data within an error lower than 2.5%.
This research investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5-20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via the injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermal characteristics of the sustainable composites that were systematically evaluated as per the ASTM standards. The addition of RF drastically altered the Delrin matrix's performance. Among the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values, which provide greater dimensional stability at high temperatures; lower CLTE, resulting in less thermal expansion; comparatively better thermal conductivity; and improved heat dissipation. Eventually, there was a moderate drop in the MFI, indicating more rigid polymer chains that restrict the flowability of the composite, thereby increasing its heat-withstanding capabilities. DSC analysis revealed a slight upward shift in Tg and increased crystallinity, suggesting restricted polymer chain mobility and enhanced load transfer at 20 wt.% RF loadings, agglomeration effects, and weaker interfacial bonding with the matrix led to deterioration in properties. Aircraft cabin components like interior panels, ducting supports, and lightweight non-structural fittings requires dimensional stability, thermal resistance, and mechanical reliability under fluctuating flight conditions.
The demand for lightweight, high-efficiency components in electric vehicles (EVs) highlights the critical need for reliable Al-Cu joints with superior electrical and thermal conductivity. While diffusion bonding has emerged as a promising approach, interfacial impurities and voids often degrade joint quality and conductivity. Conventional manual polishing was initially employed to prepare Cu and Al surfaces; however, this method proved insufficient in consistently removing oxides and contaminants, leading to non-uniform bonding. In addition, the larger surface area of the samples made traditional polishing impractical, further motivating the use of electropolishing. To overcome these limitations, we introduce electropolishing pretreatment to achieve cleaner, void-free interfaces. Electropolishing effectively dissolves surface asperities and contaminants, enabling intimate atomic contact during bonding and minimizing the formation of brittle intermetallic phases. A systematic investigation of bonding parameters was conducted using a custom-designed graphite clamping system. Microstructural analyses reveal that advanced polishing plays a pivotal role in producing uniform, impurity-free interfaces, resulting in reduced intermetallic thickness, improved bonding strength, and enhanced current-carrying capability. This study demonstrates the clear advantages of electropolishing over conventional polishing and establishes a scalable pathway to manufacture high-performance conductive joints for next-generation EV motor and power distribution systems.
This study presents a fully integrated, vehicle-level thermal management model for gasoline fuel tanks, designed to predict transient fuel temperatures, tank wall heating, and vapor generation under real-world driving conditions. The model simulates coupled thermal contributions from exhaust radiation, transient underbody airflow, conductive heat transfer, in-tank pump heating, and dynamic changes in fuel composition and level. Validation against on-road measurements shows strong agreement for fuel temperature and vapor flow profiles. Results confirm that exhaust radiative heating is the dominant thermal load, particularly during the post-shutdown heat soak period. A well-designed heat shield reduced peak tank wall temperature by approximately 27 °C, significantly lowering fuel heating and evaporation. Parametric analysis indicates that while fuel Reid Vapor Pressure (RVP) and tank material influence evaporation, their effect is secondary to external heat mitigation. While this model employs simplifications, such as assuming a uniform bulk fuel temperature and using empirically based convective correlations, these assumptions proved adequate for vehicle-level thermal management analysis. This adequacy is supported by the strong correlation between the model’s predictions and experimental field data across realistic driving scenarios. As a practical tool, the model successfully supports the optimization of thermal protection strategies and guides heat shield design decisions. Future work to incorporate measurement uncertainties, localized thermal stratification, and experimental validation of vapor composition would further strengthen predictive accuracy and extend the model's applicability to more detailed design phases.
A computational study based on a conjugate heat transfer (CHT) method in SimericsMP+ was performed to predict the winding temperatures in an X76 emotor. In this study, the thermal load was represented in the simulation through the solution of electromagnetic equations in SimericsMP+, where heat generation was driven by root-mean-square (RMS) current, while liquid cooling was applied at flow rates ranging from 1 LPM to 6 LPM. Simulations were conducted to measure the temperature on three thermocouple locations on each side of the winding crown and weld regions under steady operation. The computational strategy employed a loosely coupled approach. A fluid-only simulation was first carried out to establish stable flow conditions, followed by coupling with solid conduction where the winding acted as the heat source. The predicted temperature distributions were then compared with test data. Results obtained show good agreement, with differences remaining within an acceptable range, thereby confirming the accuracy of the numerical method. Findings demonstrate that the CHT approach not only reproduces measured winding temperatures but also provides detailed insight into local flow and temperature fields inside the emotor, information not accessible through physical testing alone. The validated methodology offers a reliable tool for guiding thermal management design and optimization of electric machines under varying cooling conditions.
Linear time-invariant (LTI) reduced-order models (ROMs) have been widely used in battery thermal management simulations due to their low hardware requirements, high computational efficiency, and good accuracy. However, the inherent assumption of LTI behavior limits their applicability in scenarios with varying coolant flow rates, where this assumption is no longer valid. To address this limitation, a novel ROM is developed by decomposing the entire battery thermal system into two subsystems. All solid components are modeled as a traditional LTI ROM, while the coolant channel is represented using Newton’s cooling law. The two subsystems are then coupled through the exchange of heat transfer rate and temperature at the fluid–solid interface between the coolant and the cold plate. Model fidelity is further enhanced by introducing a spatially distributed heat flux during the generation of the LTI ROM for solid components. Validation is performed against CFD simulations at both module and pack levels, under constant and varying flow rates. The results demonstrate that the proposed ROM achieves high accuracy while requiring several orders of magnitude less computational time than the corresponding CFD models.
Oil churning and windage power losses in dip-lubricated gearboxes can significantly affect overall transmission efficiency, particularly at high rotational speeds. As modern gearbox systems are pushed toward higher efficiency and reliability, understanding and predicting these losses becomes increasingly important. In addition to energy dissipation, the associated multiphase flow phenomena—such as oil splashing, thin film formation along gear surfaces, and aeration of the sump—strongly influence lubrication effectiveness, heat transfer, and component durability. Capturing these effects requires a robust numerical strategy that can resolve both power loss mechanisms and multiphase flow dynamics with sufficient accuracy. In this study, a single spur gear is numerically analyzed under varying oil depths and rotational speeds to quantify total power loss and investigate oil flow patterns. The computational approach employs a volume-of-fluid multiphase framework, and the predictions are systematically validated against experimental data from the OSU Lab. Validation is carried out in two stages: first, by comparing the simulated oil free-surface shapes with experimental flow visualizations for various operating conditions; and second, by comparing total power loss across a range of rotational speeds and immersion depths. The findings confirm that qualitative comparisons of oil behavior show good agreement with experimental observations including splash generation, oil streak formation, and gear surface wetting. Furthermore, predicted power loss trends align with experiments, exhibiting exponential growth with RPM and a transition toward quadratic scaling as oil depth increases. Overall, this work highlights the capability of the numerical framework to predict both churning losses and multiphase flow behavior in gear lubrication systems, providing a foundation for future gearbox design and optimization.
Gears play a critical role in automotive transmission systems. During operation, frictional heat is generated in the intermeshing region due to loading. Effective lubrication and cooling are essential to minimize heat generation and ensure smooth operation. Lubrication failure can lead to a significant local temperature rise, potentially causing gear scuffing—a phenomenon where intermeshed gear teeth weld together and tear apart during rotation—resulting in severe damage and compromised transmission performance. To prevent this, gears are typically lubricated using splash or jet lubrication techniques. This study presents a Conjugate Heat Transfer (CHT) simulation of a jet-lubricated gear pair in an automotive transmission system to predict the local temperature rise due to frictional heating in the intermeshing region of the gears. The paper focuses on implementation of the frictional heat generation on the gear teeth and resultant transient temperature rise in the gear contact region. A commercial CFD tool, Simerics MP+ is used for the 3D CHT simulation. The methodology employs a multiphase Volume of Fluid (VOF) approach to capture the interaction between oil and air while utilizing a mixed timescale coupled approach for heat transfer analysis. The resulting local temperature distribution on the gear teeth is analyzed and validated with the test data.
The objective of this paper is to evaluate the thermal performance of the brake discs in the design stage of its life cycle by developing a methodology to replicate dynamometer testing using multi-disciplinary Finite Element Analysis (FEA) methods. A simulation workflow was formulated in which Computational Fluid Dynamics (CFD) was used to create temperature and velocity dependent Heat Transfer Coefficients (HTC) which were in turn used in Computer Aided Engineering (CAE) to do a thermo-mechanical analysis. With this workflow various designs of the brake discs were analyzed. A sensitivity study was done to determine critical design features that affected its thermal performance. A final design was fixed that met both the weight and thermal performance targets. This design was evaluated in dynamometer testing, and 93% correlation was achieved. Thus, the developed simulation workflow ensured that a first-time right brake disc can be finalized in the design stage, which will meet the performance in dynamometer testing.
Battery Thermal Management Systems (BTMS) play a critical role in ensuring the longevity, safety, and efficient operation of lithium-ion battery packs. These systems are designed to better dissipate the heat generated by the cells during vehicle operation, thereby maintaining a uniform temperature distribution across the battery modules, preventing overheating and mitigating the chances of thermal runaway. However, one of the primary challenges in BTMS design lies in achieving effective thermal contact between the battery cells and the cooling plate. Non-uniform or excessive application of Thermal Interface Materials (TIMs) without ensuring robustness and uniformity can increase interfacial thermal resistance, leading to significant temperature variations across the battery modules, which may trigger power limitations via the Battery Management System (BMS) and these thermal changes can cause inefficient cooling, ultimately affecting battery performance and lifespan. In this paper, a real-world testing was conducted on the battery pack with uneven TIM application and unoptimized distribution patterns, which resulted in significant temperature variations across the pack. In contrast, the application of uniformly optimized TIM thickness reduced these temperature differences by up to 70%, demonstrating the critical impact of consistent interface design on thermal performance. To validate and further understand these findings, combined conduction-convection heat transfer model was developed using ANSYS Fluent to simulate the thermal changes of the battery pack with different TIM thicknesses alongside the unoptimized distribution patterns. The results confirmed that uneven TIM distribution contributes significantly to thermal non-uniformity within the battery pack, whereas optimizing the thickness improves overall thermal performance. Additionally, the optimized application led to a significant reduction in weight of the thermal paste (TIMs) usage, resulting in cost savings and more efficient material utilization.
The HVAC (Heating, Ventilation, and Air conditioning) system is designed to fulfil the thermal comfort requirement inside a vehicle cabin. Human thermal comfort primarily depends upon an occupant’s physiological and environmental condition. Vehicle AC performance is evaluated by mapping air velocity and local air temperature at various places inside the cabin. There is a need to have simulation methodology for cabin heating applications for cold climate to assess ventilation system effectiveness considering thermal comfort. Thermal comfort modelling involves human manikin modeling, cabin thermal model considering material details and environmental conditions using transient CAE simulation. Present study employed with LBM (Lattice-Boltzmann Method) based PowerFLOW solver coupled with finite element based PowerTHERM solver to simulate the cabin heat up. Human thermal comfort needs physiological modelling; thus, the in-built Berkeley human comfort library is used in simulation. Human thermal modelling includes metabolic rate of heat production with effects of clothing in external ambient conditions. Once human thermal modelling in a controlled environment stabilized, LBM-based solver used to predict the convective heat transfer phenomenon. Thereafter, conduction and radiation effects were solved using a coupling approach in PowerTHERM. Physical tests conducted in a controlled environment of climate chambers. Simulation results obtained correlated with experimental data. Occupants’ thermal comfort evaluated using the Berkeley comfort model. The current process further highlights the impact of heater capacity variation on in-cabin air temperature and passenger comfort level. The proposed method is helpful in thermal comfort prediction for passenger vehicles at cold ambient comfort requirements, heater capacity, and airflow delivery system effectiveness. Current process is found more effective where heater capacity and thermal comfort balance prediction are sensitive to two heaters, discussed in this paper.
Virtual reality (VR), Augmented Reality (AR) and Mixed reality (MR) are advanced engineering techniques that coalesces physical and digital world to showcase better perceiving. There are various complex physics which may not be feasible to visualize using conventional post processing methods. Various industrial experts are already exploring implementation of VR for product development. Traditional computational power is improving day-by-day with new additional features to reduce the discrepancy between test and CFD. There has been an increase in demand to replace actual tests with accurate simulation approaches. Post processing and data analysis are key to understand complex physics and resolving critical failure modes. Analysts spend a considerable amount of time analyzing results and provide directions, design changes and recommendations. There is a scope to utilize advanced features of VR, AR and MR in CFD post process to find out the root cause of any failures occurred with advanced visualization. This paper focusses on how VR can be used for 3D CFD detailed result analysis. Various physics such as Conjugate heat transfer (both steady state and transient), Discrete phase model, and Flow analysis have been integrated with VR in this study. Few case studies are also discussed, demonstrating how VR helped in understanding complex physics and provided directions for product development. After treatment systems have complex multi physics involved. Using VR, droplet interaction with exhaust gases inside the system helped in better understanding of complex physics. Steady state thermal simulation is another area where VR visualization helps to understand high temperature plume in proximity regions. This paper also focusses on the challenges experienced during integration and usage of VR. ANSYS FLUENT with Ensight are primary tools which have integrated with VR setup to utilize benefit of VR. Automated scripts have been created for ease of VR hand tools usage. Analyst issues in current post processing methods and solutions to it through VR are also discussed in this paper. Advance level implementation of AR is demonstrated in this study.
In automotive systems, efficient thermal management is essential for refining vehicle performance, enhancing passenger comfort, and reducing MAC Power Consumption. The performance of an air conditioning system is linked to the performance of its condenser, which in turn depends on critical parameters such as the opening area, radiator fan ability and shroud design sealing. The opening area decides the airflow rate through the condenser, directly affecting the heat exchange efficiency. A larger opening area typically allows for greater airflow, enhancing the condenser's ability to dissipate heat. The shroud, which guides the airflow through the condenser, plays a vital role in minimizing warm air recirculation. An optimally designed shroud can significantly improve the condenser's thermal performance by directing the airflow more effectively. Higher fan capacity can increase the airflow through the condenser, improving heat transfer rates. However, it is essential to balance fan capacity with energy consumption to achieve optimal performance. This study investigates the impact of varying these parameters on vehicle-level A/C performance and MAC Power Consumption. By systematically altering the condenser opening area, changing the shroud configuration, and adjusting the radiator fan capacity, we aim to find best conditions that enhance A/C performance and effect MAC Power Consumption. Experimental data were collected through a series of controlled tests, the results were analysed to decide the correlation between these variables A/C performance metrics such as average grill temperatures, refrigerant pressure and MAC Power Consumption. The findings provide valuable insights for automotive engineers and designers, highlighting the importance of these factors in achieving efficient as well as effective A/C systems in passenger vehicles.
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