缸盖内沸腾传热流固耦合模拟及其可靠性研究
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摘要
过冷沸腾传热是缸盖冷却水腔中存在的一种重要换热方式,然而现有的沸腾传热模型并没有考虑局部流动与发生沸腾时产生气泡对流动沸腾传热的影响,同时也没有考虑流速项对沸腾换热量、临界热流密度点及空泡份额的影响。因此,应进一步发展其模型,更加精确地模拟、预测和评价缸盖冷却水腔内的沸腾传热现象,更加合理的设计缸盖结构。本文的主要研究内容包括以下几个部分：
1、在现有的单相流沸腾换热模型的基础上,考虑流速对沸腾换热量和临界热流密度点的影响,通过数学推导建立空泡质量控制方程,利用质量与空泡份额的转换关系反映两相流的存在,基于线性叠加原理实现沸腾换热量的引入,完整描述沸腾换热曲线,进而建立新的单相均匀流沸腾换热模型,通过UDF与UDS子程序接口将模型嵌入CFD软件中进行联立求解,利用该模型的模型结果与试验结果对比表明两者结果吻合性较好。
2、为方便沸腾换热的模拟计算,在单相均匀流沸腾换热模型的基础上提出一种沸腾换热的修正算法,通过对单相对流换热的修正反映沸腾换热的影响；针对该模型在缸盖水腔设计中的应用,提出以5mm参考截面高度内的平均空泡份额值作为缸盖冷却水腔设计中沸腾换热应用的极限判据,推荐的合理取值范围应在[0.20,0.94]之间,完整的建立了沸腾换热体系。
3、基于流固耦合算法的基本思想,结合缸盖流动传热的特点,在CFD与FEA软件的基础上采用C语言与Python语言开发出一种用于缸盖冷却水腔流动传热的自动化流固耦合模拟软件；通过点云快速配准算法与MPCI自动进程控制管理实现耦合面间大规模数据的快速匹配和不同进程之间的自动排队控制,采用Python语言实现不同软件接口之间的数据传递与转换。以226-B型柴油机为例,将该算法的模拟结果与传统方法的模拟结果进行对比表明该算法具有足够的精度,具有重要的应用价值。
4、针对某柴油机缸盖,采用自行开发的自动化流固耦合算法对其进行流动传热及热负荷模拟计算分析,得到了压力场、流场分布.根据计算结果对冷却水腔结构进行更改,更改后各缸流动均匀性得到明显改善,排气门周围及喷油器周围流速得到提高。采用平均空泡份额极限值判据对冷却水腔5mm平均空泡份额值进行评判,平均空泡份额值均在极限值[0.20,0.94]之内,说明冷却水腔内沸腾状况没有出现过渡沸腾,不会发生热损坏,反映出空泡份额极限值判据比速度判据具有更为广泛的意义。考虑沸腾换热影响后,沸腾强化传热对缸盖冷却水腔内传热的作用十分明显,不可忽略。
5、采用三种实现方法利用沸腾换热修正算法对缸盖进行温度场模拟,模拟结果表明三种实现方法的结果具有较好一致性；从模拟迭代收敛时间和实现过程的难易程度上看,采用方法二进行沸腾换热的修正模拟最为合理。对比单相均匀流沸腾换热模型与修正算法的模拟结果表明两种算法的结果具有较好一致性。为验证数值模拟的准确性,在距缸盖火力面6mm处布置3个测点进行温度场测量试验。将测量结果与模拟结果进行对比：表明单相均匀流沸腾换热模型及修正算法都具有足够的模拟精度。
6、采用有限元分析方法,对缸盖进行机械、热机耦合应力模拟并在此基础上进行疲劳分析,根据模拟结果对缸盖结构提出更改措施,更改后满足强度疲劳要求；同时对比分析了沸腾换热对应力疲劳的影响,沸腾换热可以使缸盖保持在较低温度环境中工作,使缸盖鼻梁区和冷却水腔应力降低,安全系数增大,火力面的低周疲劳性得到改善,增强材料的抗热疲劳性能。
For water-cooled internal combustion engine, sub-cooled boiling heat transfer is an important heat transfer mode of cooling water-jacket in cylinder head. However the existing boiling heat transfer model does not consider the influence both of local flow and air bubbles on flow boiling heat transfer and the velocity on boiling heat transfer flux, the critical heat flux point and the void fraction. Therefore, in order to simulate, predict and evaluate the boiling heat transfer phenomena of cooling water-jacket in cylinder head more accurately and design cylinder head more rationality, the fluid-solid coupling numerical simulation of boiling heat transfer and reliability in cylinder head is studied in this paper including the following aspects:
1、Based on the existing single-phase flow boiling heat transfer model, considered the influence of velocity for boiling heat transfer flux and the critical heat flux point, a conservative void mass equation was established through theoretical analysis and mathematical derivation. The void fraction distribution of the flow was estimated indirectly by the relationship between void mass and void fraction to reflect the existence of two-phase flow. Calculated the boiling heat transfer flux by the linear superposition theory and described the boiling heat transfer curve completely, then a new homogenous flow boiling heat transfer model was established. Embedded the new boiling heat transfer model into CFD software by UDF and UDS subroutines to solve the mixed flow with single-phase flow equations and void mass equation. Comparation between the simulation results of the new boiling heat transfer model and the experimental results shows that they were achieved a good agreement.
2、For the convenience of numerical simulation of boiling heat transfer, a corrected algorithm that simulated boiling heat transfer was put forward based on the single-phase flow boiling heat transfer model. The impact of boiling heat transfer was reflected by correcting single-phase convective heat transfer. Aiming at the application of the boiling heat transfer model which is applied to the design of cylinder head, it was proposed that the critical value of mean void fraction which is located from the wall to the height of 5 mm was used as the criterion for judging the limit state of nucleate boiling of cooling water-jacket in cylinder head and to evaluate whether the boiling heat transfer in cooling water-jacket of cylinder head exceed the limit state of nucleate boiling. The reasonable mean void fraction was between 0.20 and 0.94. Then the boiling heat transfer system was established completely.
3、Based on the basic theory of fluid-solid coupled algorithm, combined with the characteristics of flow and heat transfer in cylinder head, a new automated fluid-solid numerical simulation software was developed adopting C and python language with CFD and FEA software. The point cloud quick registration algorithm is used to obtain rapid match of mass dataon coupling face. Via MPCI to control and manage the transformation of different process automation, used python language to convert and transfer data between the different software. Take 226B diesel engine for example, compared simulation results of automated fluid-solid coupled algorithm with results of traditional methods showed that this automated fluid-solid coupled algorithm had more enough precision and important industrial application value.
4、The automated numerical simulation of fluid-solid coupling on flow and boiling heat transfer of cooling water-jacket in cylinder head of diesel engine was employed using the software of CFD and FEA, and obtained the distribution of the stress field and flow field in the cooling water-jacket. According to the simulation results, the shape of cooling water-jacket was modified, the modified results showed that the flow uniformity improved obviously and the velocity around the exhaust valve and injector improved. The valve of mean void fraction which is located from the wall to the height of 5 m m in the cooling water-jacket was less than its'critical value, indicating that the nucleate boiling heat transfer in cooling water-jacket of cylinder head was safe and the criterion of mean void fraction had more extensive significance. Considered the impact of boiling heat transfer, boiling plays an evident role in enhancing heat transfer of cooling water-jacket in cylinder head, which should not be ignored in numerical calculation.
5、The numerical simulation of heat transfer in cylinder head was performed using three kinds of methods by boiling heat transfer correction algorithm, the simulation results indicated that the result of three kinds of methods have a good agreement. According to the simulation iteration convergence time and the degree of difficulty, the second method was the most reasonable one. Comparation the simulation results of the new homogenous flow boiling heat transfer model with boiling heat transfer correction algorithm, indicating that had a good agreement. In order to verify the accuracy of numerical simulation, the temperature on interior of cylinder head in diesel engine was measured using copper-constantan thermocouple. Compared the simulation results with the experimental results, the two results were in good agreement with each other, the new homogenous flow boiling heat transfer model and boiling heat transfer correction algorithm have enough simulation precision.
6、The finite element analysis for structure stress and thermal-structure stress of cylinder head were calculated and the fatigue analysis for cylinder head was calculated. According to the simulation results the shape of the cylinder head was modified, the modified results showed that the fatigue strength was improved. Meanwhile the influence of boiling heat transfer on both stress and fatigue were analyzed, it showed that cylinder head could work in a lower temperature condition because of boiling heat transfer which could reduce the thermal stress value, increase safety coefficient and intensifie their capability of preventing thermal fatigue.
1、在现有的单相流沸腾换热模型的基础上,考虑流速对沸腾换热量和临界热流密度点的影响,通过数学推导建立空泡质量控制方程,利用质量与空泡份额的转换关系反映两相流的存在,基于线性叠加原理实现沸腾换热量的引入,完整描述沸腾换热曲线,进而建立新的单相均匀流沸腾换热模型,通过UDF与UDS子程序接口将模型嵌入CFD软件中进行联立求解,利用该模型的模型结果与试验结果对比表明两者结果吻合性较好。
2、为方便沸腾换热的模拟计算,在单相均匀流沸腾换热模型的基础上提出一种沸腾换热的修正算法,通过对单相对流换热的修正反映沸腾换热的影响；针对该模型在缸盖水腔设计中的应用,提出以5mm参考截面高度内的平均空泡份额值作为缸盖冷却水腔设计中沸腾换热应用的极限判据,推荐的合理取值范围应在[0.20,0.94]之间,完整的建立了沸腾换热体系。
3、基于流固耦合算法的基本思想,结合缸盖流动传热的特点,在CFD与FEA软件的基础上采用C语言与Python语言开发出一种用于缸盖冷却水腔流动传热的自动化流固耦合模拟软件；通过点云快速配准算法与MPCI自动进程控制管理实现耦合面间大规模数据的快速匹配和不同进程之间的自动排队控制,采用Python语言实现不同软件接口之间的数据传递与转换。以226-B型柴油机为例,将该算法的模拟结果与传统方法的模拟结果进行对比表明该算法具有足够的精度,具有重要的应用价值。
4、针对某柴油机缸盖,采用自行开发的自动化流固耦合算法对其进行流动传热及热负荷模拟计算分析,得到了压力场、流场分布.根据计算结果对冷却水腔结构进行更改,更改后各缸流动均匀性得到明显改善,排气门周围及喷油器周围流速得到提高。采用平均空泡份额极限值判据对冷却水腔5mm平均空泡份额值进行评判,平均空泡份额值均在极限值[0.20,0.94]之内,说明冷却水腔内沸腾状况没有出现过渡沸腾,不会发生热损坏,反映出空泡份额极限值判据比速度判据具有更为广泛的意义。考虑沸腾换热影响后,沸腾强化传热对缸盖冷却水腔内传热的作用十分明显,不可忽略。
5、采用三种实现方法利用沸腾换热修正算法对缸盖进行温度场模拟,模拟结果表明三种实现方法的结果具有较好一致性；从模拟迭代收敛时间和实现过程的难易程度上看,采用方法二进行沸腾换热的修正模拟最为合理。对比单相均匀流沸腾换热模型与修正算法的模拟结果表明两种算法的结果具有较好一致性。为验证数值模拟的准确性,在距缸盖火力面6mm处布置3个测点进行温度场测量试验。将测量结果与模拟结果进行对比：表明单相均匀流沸腾换热模型及修正算法都具有足够的模拟精度。
6、采用有限元分析方法,对缸盖进行机械、热机耦合应力模拟并在此基础上进行疲劳分析,根据模拟结果对缸盖结构提出更改措施,更改后满足强度疲劳要求；同时对比分析了沸腾换热对应力疲劳的影响,沸腾换热可以使缸盖保持在较低温度环境中工作,使缸盖鼻梁区和冷却水腔应力降低,安全系数增大,火力面的低周疲劳性得到改善,增强材料的抗热疲劳性能。
For water-cooled internal combustion engine, sub-cooled boiling heat transfer is an important heat transfer mode of cooling water-jacket in cylinder head. However the existing boiling heat transfer model does not consider the influence both of local flow and air bubbles on flow boiling heat transfer and the velocity on boiling heat transfer flux, the critical heat flux point and the void fraction. Therefore, in order to simulate, predict and evaluate the boiling heat transfer phenomena of cooling water-jacket in cylinder head more accurately and design cylinder head more rationality, the fluid-solid coupling numerical simulation of boiling heat transfer and reliability in cylinder head is studied in this paper including the following aspects:
1、Based on the existing single-phase flow boiling heat transfer model, considered the influence of velocity for boiling heat transfer flux and the critical heat flux point, a conservative void mass equation was established through theoretical analysis and mathematical derivation. The void fraction distribution of the flow was estimated indirectly by the relationship between void mass and void fraction to reflect the existence of two-phase flow. Calculated the boiling heat transfer flux by the linear superposition theory and described the boiling heat transfer curve completely, then a new homogenous flow boiling heat transfer model was established. Embedded the new boiling heat transfer model into CFD software by UDF and UDS subroutines to solve the mixed flow with single-phase flow equations and void mass equation. Comparation between the simulation results of the new boiling heat transfer model and the experimental results shows that they were achieved a good agreement.
2、For the convenience of numerical simulation of boiling heat transfer, a corrected algorithm that simulated boiling heat transfer was put forward based on the single-phase flow boiling heat transfer model. The impact of boiling heat transfer was reflected by correcting single-phase convective heat transfer. Aiming at the application of the boiling heat transfer model which is applied to the design of cylinder head, it was proposed that the critical value of mean void fraction which is located from the wall to the height of 5 mm was used as the criterion for judging the limit state of nucleate boiling of cooling water-jacket in cylinder head and to evaluate whether the boiling heat transfer in cooling water-jacket of cylinder head exceed the limit state of nucleate boiling. The reasonable mean void fraction was between 0.20 and 0.94. Then the boiling heat transfer system was established completely.
3、Based on the basic theory of fluid-solid coupled algorithm, combined with the characteristics of flow and heat transfer in cylinder head, a new automated fluid-solid numerical simulation software was developed adopting C and python language with CFD and FEA software. The point cloud quick registration algorithm is used to obtain rapid match of mass dataon coupling face. Via MPCI to control and manage the transformation of different process automation, used python language to convert and transfer data between the different software. Take 226B diesel engine for example, compared simulation results of automated fluid-solid coupled algorithm with results of traditional methods showed that this automated fluid-solid coupled algorithm had more enough precision and important industrial application value.
4、The automated numerical simulation of fluid-solid coupling on flow and boiling heat transfer of cooling water-jacket in cylinder head of diesel engine was employed using the software of CFD and FEA, and obtained the distribution of the stress field and flow field in the cooling water-jacket. According to the simulation results, the shape of cooling water-jacket was modified, the modified results showed that the flow uniformity improved obviously and the velocity around the exhaust valve and injector improved. The valve of mean void fraction which is located from the wall to the height of 5 m m in the cooling water-jacket was less than its'critical value, indicating that the nucleate boiling heat transfer in cooling water-jacket of cylinder head was safe and the criterion of mean void fraction had more extensive significance. Considered the impact of boiling heat transfer, boiling plays an evident role in enhancing heat transfer of cooling water-jacket in cylinder head, which should not be ignored in numerical calculation.
5、The numerical simulation of heat transfer in cylinder head was performed using three kinds of methods by boiling heat transfer correction algorithm, the simulation results indicated that the result of three kinds of methods have a good agreement. According to the simulation iteration convergence time and the degree of difficulty, the second method was the most reasonable one. Comparation the simulation results of the new homogenous flow boiling heat transfer model with boiling heat transfer correction algorithm, indicating that had a good agreement. In order to verify the accuracy of numerical simulation, the temperature on interior of cylinder head in diesel engine was measured using copper-constantan thermocouple. Compared the simulation results with the experimental results, the two results were in good agreement with each other, the new homogenous flow boiling heat transfer model and boiling heat transfer correction algorithm have enough simulation precision.
6、The finite element analysis for structure stress and thermal-structure stress of cylinder head were calculated and the fatigue analysis for cylinder head was calculated. According to the simulation results the shape of the cylinder head was modified, the modified results showed that the fatigue strength was improved. Meanwhile the influence of boiling heat transfer on both stress and fatigue were analyzed, it showed that cylinder head could work in a lower temperature condition because of boiling heat transfer which could reduce the thermal stress value, increase safety coefficient and intensifie their capability of preventing thermal fatigue.
引文
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