Heat transfer numerical calculation of ventilated brake disc with internal fusion heat pipe
Article Text (Baidu Translation)
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摘要: 为强化现有通风刹车盘(VBD)的散热，防止其发生热衰退，提高车辆的刹车安全性，提出了一种体内融合整体热管的新型通风刹车盘，即热管盘(HPD)；为检验HPD的传热性能及其改进效果，在相同工况的条件下对HPD、VBD进行了基于FLUENT的详细的传热数值模拟计算，通过数值计算探究了HPD的传热性能与3个影响因素，即充液率、热流密度、转速的内在关系，并将HPD、VBD的传热性能进行对比。研究结果表明：HPD的最佳充液率在小热流密度下(不大于4 700 W·m-2)为35%，在大热流密度下(大于4 700 W·m-2)为40%；HPD的热阻会随热流密度增加而下降，随转速的升高而增加；HPD传热效果较VBD有显著提升，譬如在充液率为35%、转速为23.1 rad·s-1、热流密度为5 839 W·m-2时，HPD的盘面平均温度及盘面最高温度较VBD可分别下降49和53 K，同时热阻可降低28%；HPD的盘面平均温度偏差虽略高于VBD，但因其强大的散热能力，HPD的局部超温反而得到改善；HPD联通空间设置的承压块保证了其结构强度和承压能力，且其预测失效循环次数较VBD还可增加269次。可见，提出的新型热管盘从强化传热着手，可明显降低其工作温度，从而提高通风刹车盘的寿命与刹车安全性。Abstract: In order to strengthen the heat dissipation of existing ventilated brake discs (VBDs), prevent thermal degradation, and improve the braking safety of vehicles, a new type of VBD incorporating an integral heat pipe in the body, i.e., heat pipe disc (HPD), was proposed. To examine the heat transfer performance of HPD and its improvement effect, detailed FLUENT-based numerical simulation calculations of heat transfer in both HPD and VBD were conducted under the same working conditions. The intrinsic relationships between the heat transfer performance of HPD and three influencing factors, namely liquid filling rate, heat flow density, and rotational speed, were investigated through numerical calculations, and the heat transfer performance of HPD was compared to that of VBD. Research results show that the optimal liquid filling rate of HPD is 35% at low heat flow densities (not exceeding 4 700 W·m-2) and 40% at high heat flow densities (exceeding 4 700 W·m-2). The thermal resistance of HPD decreases with increasing heat flow density and increases with increasing rotational speed. The heat transfer effect of HPD has been significantly improved compared to VBD. For example, at a liquid filling rate of 35%, rotational speed of 23.1 rad·s-1, and heat flow density of 5 839 W·m-2, the average and maximum temperatures of the surface of HPD reduce by 49 K and 53 K, respectively, compared to VBD. At the same time, the thermal resistance reduces by 28%. Although the deviation of the average temperature of the surface of HPD is slightly higher than that of VBD, the local over-temperature of HPD has been improved due to its superior heat dissipation ability. The pressurized blocks in the connecting space of HPD ensure its structural strength and pressure-bearing capacity. As a result, its predicted number of failure cycles is 269 times higher than that of VBD. So the proposed HPD can significantly reduce its operating temperatures by enhancing heat transfer, thus improving the lifespan and safety of VBD.
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Key words:
- automotive engineering /
- ventilated brake disc /
- numerical simulation /
- heat pipe /
- two-phase flow /
- heat transfer
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图 5 不同充液率下平均温度随热流密度变化
Figure 5. Variations of average temperature with heat flow density for different liquid filling rates
图 6 不同充液率下热阻随热流密度变化
Figure 6. Variations of thermal resistance with heat flow density for different liquid filling rates
图 7 不同转速下对流换热系数变化
Figure 7. Variation of convective heat transfer coefficient for different rotational speeds
图 8 不同转速下盘面平均温度随热流密度变化
Figure 8. Variations of average temperature of disk surface with heat flow density at different rotational speeds
图 9 不同转速下热阻随热流密度变化
Figure 9. Variations of thermal resistance with heat flow density at different rotational speeds
图 10 HPD和VBD的盘面平均温度比较
Figure 10. Comparison of average temperatures of disk surface for HPD and VBD
表 1 HPD与VBD的结构尺寸
Table 1. Structural dimensions of HPD and VBD
参数 HPD VBD 盘片外径/mm 200 200 盘片内径/mm 100 100 盘片厚度(含中空)/mm 11 5 叶片数/片 12 12 盘片间距/mm 5 5 盘片1壁厚度/mm 2 盘片2壁厚度/mm 3 承压块数/块 12 
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表 2 制动盘的疲劳性能参数
Table 2. Fatigue performance parameters of brake disc
参数 疲劳强度系数/ MPa 疲劳延性系数 疲劳延性指数 疲劳强度系数 不锈钢304 985 0.103 -0.255 -0.102
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