开式热沉内冷刀具的设计及其导热性能分析

车削加工温度对工件的表面加工质量和刀具的使用寿命具有重要影响. 设计了一种开式热沉内冷刀具,计算了在实际加工工艺参数下刀具受到的切削力和前刀面上的热流密度,分析了刀具的结构强度;建立了刀具热-流-固耦合温度场模型,探讨了热稳态条件下刀具的温度场分布,以及刀片冷却液流道内热沉数量对刀具导热性能的影响规律,比较了在相同热源条件下开式热沉内冷刀具与其他内冷刀具的导热性能. 结果表明:对于刀片材料为硬质合金YT5的刀具,在热流密度为10 W/mm2的条件下,内置6个热沉的设计方案可获得最佳冷却效果,刀具的最高切削温度控制为187.1 ℃;与其他内冷刀具相比,开式热沉内冷刀具的最高切削温度降低了12.1 ℃.      

Integrated microthermoelectric cooler for microfluidic channels

Precise fluid temperature control in microfluidic channels is a requirement for many lab-on-a-chip and microreactor devices, especially in biotechnology where most processes are highly temperature sensitive. We demonstrate the concept of a microthermoelectric cooler integrated into a microfluidic channel in order to give rapid and localised fluid cooling. The key aspect of this concept is the use of a second imbedded microfluidic channel that is used as a miniature heat sink. An analytical thermal model has been derived that couples thermoelectric effects with fluid heat-transfer rates from both the hot and cold connections. Using this model, the effect on cooling performance of varying the thermal resistance between the hot and cold connections and the fluid has been quantified, as well as the effect of substrate thermal conductivity. If the substrate thermal conductivity is too high, heat leakage renders the thermoelectric cooler ineffective. The optimum electrical current for cooling has been shown to be a function of the thermal resistance of the heat sink. For thermoelectric coolers there is competition between temperature reduction and cooling power. Using this fact, based on the final fluid temperature required, we have calculated the maximum flow rate that will achieve this. Finally, a prototype integrated microthermoelectric cooler has been fabricated and tested.     

The influence of fluid properties on electrohydrodynamic heat transfer enhancement in liquids under viscous and electrically dominated flow conditions

Fluid property effects on electrohydrodynamic (EHD) heat transfer enhancement were investigated. Heat transfer, pressure drop, electrical power requirements, and the transition between the viscous dominated and electrically dominated flow regimes as a function of fluid properties were examined using three cooling oils having widely varying physical properties. Low viscosity and low electrical conductivity gave the greatest heat transfer enhancement for a given electrical power input. The required electrical power to achieve a specified heat transfer enhancement was greater for working fluids that had a small charge relaxation time, defined as the ratio of the electrical permittivity to the electrical conductivity. These results correlate well with available experimental and analytical data. A theoretical prediction of the effect of fluid properties and forced flow rate on the onset of EHD enhancement was experimentally verified. The onset of significant EHD heat transfer enhancement occurs most readily in low viscosity liquids at low Reynolds number flows for a given electrical power input.     

Numerical study of the natural convective cooling of a vertical plate

We study numerically in this paper the natural convective cooling of a vertical plate. The full transient heat conduction equation for the plate, coupled with the natural convection boundary layer equations are solved numerically for a wide range of the parametric space. Assuming a large Rayleigh number for the natural convection flow, the balance equations are reduced to a system of three differential equations with three parameters: the Prandtl number of the fluid, Pr, a non-dimensional plate thermal conductivity α and the aspect ratio of the plate ?. The nondimensional cooling time depends mainly on α/?², obtaining a minimum of this time for values of 1?α??².     

Mathematical modeling of heat transfer in a heat-shielding material

The interaction of the cooling systems of permeable materials with a high-temperature gas flow is considered. The effect of the porosity and thermal properties of some metals on heat transfer is studied. It is found that increasing the thermal conductivity of the material leads to a decrease in the temperature of the heat-shielding coating and increasing the porosity to a more uniform distribution of the coolant applied on the surface and to a decrease in the heat loads on the structure to be protected.     

Thermodynamic analytical model of a loop heat pipe

A thermodynamics analytical model is developed to explore different parameters effects on a loop heat pipe (LHP). The LHP is a two-phase device with extremely high effective thermal conductivity that utilizes the thermodynamic pressure difference to circulate a cooling fluid. The effects of pipe length, pipe diameter, condenser temperature, and heat load are reported. As pipe length increases and/or pipe diameter decreases, a higher temperature is expected in the evaporator.     

Destabilization of film boiling by means of a thermal resistance

Described is the type of vaporisation which takes place when a thermal resistance, consisting in a film of a substance of low heat conductivity, is placed between the surface of a quenched sample and the cooling liquid. This type of vaporisation, larvate boiling, is characterised by an alternate wetting/non-wetting of the solid surface.Two conditions are necessary for larvate boiling: thermal resistance and surface effusivity.Substituting larvate boiling for film boiling allows the heat flux between a solid surface at high temperature and the cooling liquid to be greatly increased.     

Analytical approximation for solidification processes in PCM storage with internal fins: imposed heat flux

Uses of thermal energy storage systems have expanded notably in recent decades. In thermal energy systems, internal heat transfer enhancement techniques such as fins are often used because of the low thermal conductivity of the phase change materials (PCMs). In this paper, solidification of a PCM is studied in a rectangular storage with horizontal internal plate fins and an imposed constant heat flux on the vertical walls. A simplified analytical solution is presented and its results are compared to those for a numerical approach based on an enthalpy method. The fraction of solidified PCM in storage is calculated with the derived analytical model which determines how much of the storage is solidified after a certain time. The results show that the analytical model satisfactorily estimates the solid–liquid interface and the temperature distribution for the fin, which are useful in the design of PCM-based thermal energy storage or cooling systems.     

Numerical simulation of heat transfer in a micro channel heat sinks using nanofluids

In this study, a numerical simulation of copper microchannel heatsink (MCHS) using nanofluids as coolants is presented. The nanofluid is a mixture of pure water and nanoscale metallic or nonmetallic particles with various volume fractions. Also, the effects of various volume fractions, volumetric flow rate and various materials of nanoparticles on the performance of MCHS have been developed. A three-dimensional computational fluid dynamics model was developed using the commercial software package FLUENT, to investigate the conjugate fluid flow and heat transfer phenomena in micro channel heatsinks. The results show that the cooling performance of a microchannel heat sink with water based nanofluid containing Al₂O₃ (vol 8%) is enhanced by about 4.5% compared with micro channel heatsink with pure water. Nanofluids reduce both the thermal resistance and the temperature difference between the top (heated) surface of the MCHS and inlet nanofluid compared with that pure water. The cooling performance of a micro channel heat sink with metal nanofluids improves compared with that of a micro channel heat sink with oxide metal nanofluids because the thermal conductivity of metal nanofluid is higher than oxide metal nanofluids. Micro channel heat sinks with nanofluids are expected to be good candidates as the next generation cooling devices for removing ultra high heat flux.     

Distribution of Friction Heat Between a Stationary Pin and Rotating Ring

The analysis of the heat distribution between a stationary pin and rotating ring was considered. To solution of the governing quasi-stationary heat conductivity equation the finite Fourier transform was used. The convective cooling from outer and internal surface of the ring as the boundary conditions were considered. The ring surface temperature, the average temperature on the ring surface and the heat distribution coefficient for the studied system were determined. The numerical results for the temperatures and heat distribution coefficient which demonstrated the effects of the Biot number and internal radius of the ring on them, were presented.     

A Numerical Investigation of Transpiration Cooling with Liquid Coolant Phase Change

This article presents a numerical approach to investigate the transpiration cooling problems with coolant phase change within porous matrix. A new model is based on the coupling of the two-phase mixture model (TPMM) with the local thermal non- equilibrium (LTNE), and used to describe the liquid coolant phase change and heat exchange processes in this article. The effects of thermal conductivity, porosity, and sphere diameter of the porous matrix on the temperature and saturation distributions within the matrix are studied. The results indicate that an increase in the porosity or sphere diameter can lead to an area dilation of two-phase region and a rise of liquid temperature; whereas an increase in the thermal conductivity of the porous matrix results only in a rise of liquid temperature, but drops of solid temperature and temperature gradient on the hot surface. The influence of hot surface pressure on cooling effect is discussed by numerical simulations, and numerical results show that the effect of the transpiration cooling will be worse under higher pressure. The investigation also discovers an inverse phenomenon to the past investigations on the transpiration cooling without coolant phase change, namely in two-phase region, coolant temperature may be higher than solid temperature. This inversion can be captured only by the new LTNE–TPMM.     

Interaction of surface radiation with conjugate mixed convection from a vertical channel with multiple discrete heat sources

Important results of a numerical study performed on combined conduction–mixed convection–surface radiation from a vertical channel equipped with three identical flush-mounted discrete heat sources in its left wall are provided here. The channel has walls of identical height with the spacing varied by varying its aspect ratio (AR). The cooling medium is air that is considered to be radiatively transparent. The heat generated in the channel gets conducted along its walls before getting dissipated by mixed convection and radiation. The governing equations for fluid flow and heat transfer are considered without boundary layer approximations and are transformed into vorticity–stream function form and are later normalized. The resulting equations are solved, along with relevant boundary conditions, making use of the finite volume method. The computer code written for the purpose is validated both for fluid flow and heat transfer results with those available in the literature. Detailed parametric studies have been performed and the effects of modified Richardson number, surface emissivity, thermal conductivity and AR on various pertinent results have been looked into. The significance of radiation in various regimes of mixed convection has been elucidated. The relative contributions of mixed convection and radiation in carrying the mandated cooling load have been thoroughly explored.     

Effect of Conduction in Bottom Wall on B��nard Convection in a Porous Enclosure with Localized Heating and Lateral Cooling

Darcy-Bénard convection in a square porous enclosure with a localized heating from below and lateral cooling is studied numerically in the present paper. A finite-thickness bottom wall is locally heated, the top wall is kept at a lower temperature than the bottom wall temperature, and the lateral walls are cooled. The finite difference method has been used to solve the dimensionless governing equations. The analysis in the undergoing numerical investigation is performed in the following ranges of the associated dimensionless groups: the heat source length?? ${0.2\leq H \leq 0.9}$ , the wall thickness?? ${0.05\leq D \leq 0.4}$ , the thermal conductivity ratio?? ${0.8\leq K_{\rm r} \leq 9.8}$ , and the Biot number?? ${0.1\leq Bi \leq 1.1}$ . It is observed that the heat transfer rate could increase with increasing heat source lengths, thermal conductivity ratio, and cooling intensity. There exists a critical wall thickness for a high wall conductivity below which the increasing wall thickness increases the heat transfer rate and above which the increasing wall thickness decreases the heat transfer rate.     

A comparison of two formulations of the fin efficiency for straight fins

A formulation of the fin efficiency based on Newton’s law of cooling is compared with a formulation based on a ratio of heat transferred from the fin surface to the surrounding fluid to the heat conducted through the base.The first formulation requires that the solution of the nonlinear fin equations for constant heat transfer coefficient and constant thermal conductivity is known,whilst the second formulation of the fin efficiency requires only that a first integral of the model equation is known.This paper shows the first formulation of the fin efficiency contains approximation errors as only power series and approximate solutions to the nonlinear fin equations have been determined.The second formulation of the fin efficiency is exact when the first integrals can be determined.     

Molten droplet solidification and substrate remelting in microcasting Part I: numerical modeling and experimental verification

This paper presents a numerical model of a molten metal droplet impinging, solidifying and bonding to a solid substrate. The physical and numerical model includes dissimilar materials, multi-dimensional axisymmetric heat transfer, tracking of solid/liquid interfaces during remelting and solidification, and coupled treatment of the continuous droplet/substrate region. The numerical model solves for the evolution of the temperature distribution in the droplet and substrate, predicts the position of the remelting and solidification fronts, and accounts for convective motion. The effect of the convection induced by the droplet spreading is modeled through a time-dependent effective thermal conductivity. High-speed filming of the molten droplet impinging and spreading on the substrate is performed to obtain the required parameters to determine this time dependent effective conductivity. The accuracy of the model is investigated with experimental techniques. This research is directly related to the development of microcasting Shape Deposition Manufacturing (SDM) which is a process for automatically fabricating complex multi-material objects by sequentially depositing material layers. Microcasting is a molten metal droplet deposition process in SDM, which is able to create fully dense metal layers with controlled microstructure. Important issues in the production of high quality objects manufactured with microcasting SDM are: attainment of interlayer metallurgical bonding through substrate remelting, control of both substrate and droplet cooling rates, and minimization of residual thermal stresses. To validate experimentally the numerical modeling approach, predicted cooling rates are compared with thermocouple measurements and substrate remelting depths are verified through optical metallographic techniques. Received on 10 June 1998     

Effect of temperature gradient within a solid particle on the rotation and oscillation modes in solid-dispersed two-phase flows

Liquid–solid two-phase flow with heat transfer is simulated, and the effect of temperature gradient within a solid particle on the particle behaviour and heat transfer is studied. The interaction between fluid and particles is considered with our original immersed solid approach on a rectangular grid system. The local heat flux at the fluid–solid interface is described with an anisotropic heat conductivity matrix, and the governing equation of temperature is time-updated with an implicit treatment for the diffusion term. The method is applied to a 2-D natural convection flow of a relatively low Rayleigh number including multiple particles. Heat transfer and particle behaviours are studied for different solid heat conductivities (ratio to the fluid conductivity ranging between 10⁻³ and 10³) and solid volume fractions. Under a condition of relatively low heat conductivity ratio, the particles show a simple circulating flow. By increasing the heat conductivity ratio, a transition of the particulate flow is observed to oscillation mode around the domain centre due to the buoyancy force as a restitution force. The oscillation period is found to vary with the heat conductivity ratio, and it is related to the time scales for the heat transfer via fluid and solid.     

A study on heat transfer of the optimization in circular fins of parabolic profile with variable thermal parameters

Circular fins are used extensively in heat exchange devices to increase the heat transfer. For economic purposes, the traditional approach to the optimization of fins consists of minimizing the comsumption (investment) of fin material for the excution of a specified heat transfer task. The minimum weight cooling fin has optional profile to be a concave parabola. Therefore, the optimum geometric dimensions of circular fins of parabolic profile with variable thermal parameters are studied. The effect of the two pertinent physical parameters-thermal conductivity variation parameter α and the index of the heat transfer coefficient variationm upon the optimum geometric dimensions is also studied. The results pressented can be used as the design guideline for engineering practice.     

Interaction of surface radiation with combined conduction and convection from a discretely heated L-corner

Prominent results pertaining to the problem of multi-mode heat transfer from an L-corner equipped with three identical flush-mounted discrete heat sources in its left leg are given here. The heat generated in the heat sources is conducted along the two legs of the device before being dissipated by combined convection and radiation into air that is considered to be the cooling agent. The governing equations for temperature distribution along the L-corner are obtained by making appropriate energy balance between the heat generated, conducted, convected and radiated. The non-linear partial differential equations thus obtained are converted into algebraic form using a finite-difference formulation. The resulting equations are solved simultaneously by Gauss–Seidel iterative solver. A computer code is specifically written to solve the problem. The computational domain is discretised using 101 grids along the left leg, with 15 grids taken per heat source, and 21 grids along the bottom leg. The effects of surface emissivity, convection heat transfer coefficient, thermal conductivity and aspect ratio on local temperature distribution, peak device temperature and relative contributions of convection and radiation to heat dissipation from the L-corner are studied in detail. The point that one cannot overlook radiation in problems of this class has been clearly elucidated.