天然气发动机气缸盖热负荷及冷却水腔内沸腾传热研究
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摘要
冷却系统是发动机的重要组成部分,起到控制发动机热负荷水平的作用,其性能的优劣还影响到整机的结构紧凑性、动力性、燃油经济性和排放性能。在发动机冷却系统的开发过程中,合理地利用沸腾传热机制的高换热能力有利于强化冷却水腔内的换热强度,从而提高冷却系统的工作效率、改善整机的工作性能。然而,过度的沸腾也可能导致冷却系统内“气阻”故障的发生或“过热点”的出现,以至影响到发动机的正常运行。现代发动机冷却系统的设计理念认为冷却水腔内最理想的传热方式是以对流换热为主而辅以适度的沸腾换热,这样就可以综合利用强制对流换热的稳定性与泡核沸腾传热的高换热能力。因此,这就需要对冷却水腔内的换热形式与换热强度,尤其是冷却水腔内的沸腾状况实现准确地预测与合理地控制。
本文以车用天然气发动机为研究对象,进行了冷却系统的工作状况对发动机热平衡与气缸盖工作温度影响的试验研究。结果表明,该发动机冷却水腔内存在着不同程度的沸腾现象,由于沸腾传热的存在,导致发动机冷却水温与冷却系统的工作压力对气缸盖各区域工作温度存在不同程度的影响；其中,冷却水温对高温区域的影响较小、对低温区域的影响较大,而冷却系统压力对高温区域的影响较大、对低温区域的影响较小。
为了准确地预测发动机冷却水腔内的换热形式与换热强度,一方面,基于Kandlikar的分区方法与冷却水腔模拟通道内的试验数据,建立了适应性更好、计算精度更高的沸腾传热模型；另一方面,结合直接耦合算法与顺序耦合算法,建立了包括冷却水腔内流动换热、气缸盖内固体导热及缸内进排气燃烧在内的三维气固液多场耦合仿真系统。结果表明,在发动机多场耦合仿真系统中嵌入以上沸腾传热模型可以提高其计算精度,并实现冷却水腔内沸腾状况的有效预测。
为了分析发动机冷却水腔内的气泡分布状况,基于欧拉均相流控制方程,建立了适应性更好的沸腾两相流模型,并将其用于该发动机冷却水腔内沸腾两相流的计算与分析。结果表明,由于流动死水区的存在,导致在气缸盖上层水腔靠近排气道的区域出现了气泡聚集的状况,指出该发动机冷却水腔内的水流分布状况有待进一步优化。
结合试验测量与数值模拟,分析了发动机在不同冷却液温度与不同冷却系统压力下冷却水腔内的沸腾状况及其对气缸盖热负荷的影响趋势。结果表明,单纯地降低冷却水的温度或提高冷却系统的压力可以提高冷却系统的抗气蚀压力,从而降低冷却系统发生气蚀的故障率；然而,过低的冷却水温与过高的冷却系统压力削弱了冷却水腔内的沸腾状况,导致气缸盖热应力有所增大,使其热疲劳强度有所降低。分析结果进一步表明,在气缸盖工作温度处于材料允许温度范围内时,通过同时提高冷却水的温度与冷却系统的压力可以强化冷却水腔热关键区域的沸腾状况,从而在保证冷却系统抗气蚀压力的前提下降低气缸盖承受的热应力与气缸盖的热负荷水平。
通过以上研究,最终实现了冷却水腔内换热形式与换热强度的有效预测,并为冷却水腔内沸腾状况的合理控制提供了参考依据。
The cooling system is an important part of an engine, serving to control the engine thermal load, whose performance also affects the structure size, power, fuel economy and exhaust emission of the engine. The local heat transfer would be greatly enhanced if boiling regime is properly utilized in the development of the cooling system of an engine, which improves the work efficiency of the cooling system and the performance of the whole engine. However, excessive boiling inside the cooling gallery would cause vapor lock failures and hot spots in heated components, which further affect the normal operation of the engine. The modern design concept of cooling systems considers that the best heat transfer mechanism inside cooling galleries is convective heat transfer supplemented with moderate boiling, which promotes comprehensive utilization of stability of convective heat transfer and high heat transfer ability of boiling. Thus accurate prediction and reasonably control of the heat transfer mechanism and boiling intensity inside the cooling galleries must be achieved.
A vehicle natural gas engine was taken as the research object in this thesis, a thermal balance test and cylinder head temperature measurement experiment at different cooling system working conditions was conducted. The results show that various degrees of boiling are expected inside the cooling gallery and the coolant temperature and system pressure affect different zones in the cylinder head by different level, upon which the coolant temperature has negligible effects on the high temperature zones and shows apparent effects on the low temperature zones, while the system pressure has apparent effects on the high temperature zones and shows negligible effects on the low temperature zones.
In order to realize accurate prediction of the boiling intensity inside the cooling gallery, a boiling heat transfer model with improved flexibility and calculation accuracy was proposed based on Kandlikar's division description method and experiment data obtained in a cooling gallery simulator passage, otherwise, a multi-field coupled system including the flow heat transfer inside the cooling gallery, the heat conduction in the cylinder head and the combustion process inside the cylinder was established. The results show that the computational error is reduced and effective prediction of the heat transfer mechanism and intensity inside the cooling gallery is realized due to the incorporation of the proposed model in the multi-field coupled system.
In order to analyze the vapor distribution inside the engine cooling gallery, a two-phase boiling flow model is established based on the framework of Euler mixture equations. On that basis, the two-phase boiling flow inside the engine cooling gallery is simulated and analyzed. The results show that bubble congestion is expected in the area located in the upper water gallery besides the exhaust port due to the presence of flow stagnation zone, suggesting that the flow distribution condition inside the engine cooling gallery need to be further optimized.
The boiling condition inside the engine cooling gallery as well as its effect on the thermal load of the cylinder head was analyzed by experiment measurement and numerical simulation. The results show that both reduction in coolant temperature and rise in system pressure could increase the anti-cavitation pressure of the cooling system, which reduce the cavitation failure rate of the cooling system, however, the thermal stress on the cylinder head is increased as it weak the boiling intensity inside the cooling gallery, leading to decrease in the engine thermal fatigue strength. The results further indicate that when the metal temperature is among the allowable range of the cylinder head material, simultaneously increasing the coolant temperature and the system pressure could enhance the boiling intensity in thermal critical areas and decrease the thermal stress as well as the thermal load of the cylinder head after ensuring the anti-cavitation pressure of the cooling system.
Through above study, effective prediction of the heat transfer mechanism and intensity inside the cooling gallery was realized, and guidance for reasonable control of the boiling condition was provided.
本文以车用天然气发动机为研究对象,进行了冷却系统的工作状况对发动机热平衡与气缸盖工作温度影响的试验研究。结果表明,该发动机冷却水腔内存在着不同程度的沸腾现象,由于沸腾传热的存在,导致发动机冷却水温与冷却系统的工作压力对气缸盖各区域工作温度存在不同程度的影响；其中,冷却水温对高温区域的影响较小、对低温区域的影响较大,而冷却系统压力对高温区域的影响较大、对低温区域的影响较小。
为了准确地预测发动机冷却水腔内的换热形式与换热强度,一方面,基于Kandlikar的分区方法与冷却水腔模拟通道内的试验数据,建立了适应性更好、计算精度更高的沸腾传热模型；另一方面,结合直接耦合算法与顺序耦合算法,建立了包括冷却水腔内流动换热、气缸盖内固体导热及缸内进排气燃烧在内的三维气固液多场耦合仿真系统。结果表明,在发动机多场耦合仿真系统中嵌入以上沸腾传热模型可以提高其计算精度,并实现冷却水腔内沸腾状况的有效预测。
为了分析发动机冷却水腔内的气泡分布状况,基于欧拉均相流控制方程,建立了适应性更好的沸腾两相流模型,并将其用于该发动机冷却水腔内沸腾两相流的计算与分析。结果表明,由于流动死水区的存在,导致在气缸盖上层水腔靠近排气道的区域出现了气泡聚集的状况,指出该发动机冷却水腔内的水流分布状况有待进一步优化。
结合试验测量与数值模拟,分析了发动机在不同冷却液温度与不同冷却系统压力下冷却水腔内的沸腾状况及其对气缸盖热负荷的影响趋势。结果表明,单纯地降低冷却水的温度或提高冷却系统的压力可以提高冷却系统的抗气蚀压力,从而降低冷却系统发生气蚀的故障率；然而,过低的冷却水温与过高的冷却系统压力削弱了冷却水腔内的沸腾状况,导致气缸盖热应力有所增大,使其热疲劳强度有所降低。分析结果进一步表明,在气缸盖工作温度处于材料允许温度范围内时,通过同时提高冷却水的温度与冷却系统的压力可以强化冷却水腔热关键区域的沸腾状况,从而在保证冷却系统抗气蚀压力的前提下降低气缸盖承受的热应力与气缸盖的热负荷水平。
通过以上研究,最终实现了冷却水腔内换热形式与换热强度的有效预测,并为冷却水腔内沸腾状况的合理控制提供了参考依据。
The cooling system is an important part of an engine, serving to control the engine thermal load, whose performance also affects the structure size, power, fuel economy and exhaust emission of the engine. The local heat transfer would be greatly enhanced if boiling regime is properly utilized in the development of the cooling system of an engine, which improves the work efficiency of the cooling system and the performance of the whole engine. However, excessive boiling inside the cooling gallery would cause vapor lock failures and hot spots in heated components, which further affect the normal operation of the engine. The modern design concept of cooling systems considers that the best heat transfer mechanism inside cooling galleries is convective heat transfer supplemented with moderate boiling, which promotes comprehensive utilization of stability of convective heat transfer and high heat transfer ability of boiling. Thus accurate prediction and reasonably control of the heat transfer mechanism and boiling intensity inside the cooling galleries must be achieved.
A vehicle natural gas engine was taken as the research object in this thesis, a thermal balance test and cylinder head temperature measurement experiment at different cooling system working conditions was conducted. The results show that various degrees of boiling are expected inside the cooling gallery and the coolant temperature and system pressure affect different zones in the cylinder head by different level, upon which the coolant temperature has negligible effects on the high temperature zones and shows apparent effects on the low temperature zones, while the system pressure has apparent effects on the high temperature zones and shows negligible effects on the low temperature zones.
In order to realize accurate prediction of the boiling intensity inside the cooling gallery, a boiling heat transfer model with improved flexibility and calculation accuracy was proposed based on Kandlikar's division description method and experiment data obtained in a cooling gallery simulator passage, otherwise, a multi-field coupled system including the flow heat transfer inside the cooling gallery, the heat conduction in the cylinder head and the combustion process inside the cylinder was established. The results show that the computational error is reduced and effective prediction of the heat transfer mechanism and intensity inside the cooling gallery is realized due to the incorporation of the proposed model in the multi-field coupled system.
In order to analyze the vapor distribution inside the engine cooling gallery, a two-phase boiling flow model is established based on the framework of Euler mixture equations. On that basis, the two-phase boiling flow inside the engine cooling gallery is simulated and analyzed. The results show that bubble congestion is expected in the area located in the upper water gallery besides the exhaust port due to the presence of flow stagnation zone, suggesting that the flow distribution condition inside the engine cooling gallery need to be further optimized.
The boiling condition inside the engine cooling gallery as well as its effect on the thermal load of the cylinder head was analyzed by experiment measurement and numerical simulation. The results show that both reduction in coolant temperature and rise in system pressure could increase the anti-cavitation pressure of the cooling system, which reduce the cavitation failure rate of the cooling system, however, the thermal stress on the cylinder head is increased as it weak the boiling intensity inside the cooling gallery, leading to decrease in the engine thermal fatigue strength. The results further indicate that when the metal temperature is among the allowable range of the cylinder head material, simultaneously increasing the coolant temperature and the system pressure could enhance the boiling intensity in thermal critical areas and decrease the thermal stress as well as the thermal load of the cylinder head after ensuring the anti-cavitation pressure of the cooling system.
Through above study, effective prediction of the heat transfer mechanism and intensity inside the cooling gallery was realized, and guidance for reasonable control of the boiling condition was provided.
引文
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