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Manufacturing Technology Insights | Thursday, January 12, 2023
With the advent of additive manufacturing and software tools, many thermal management applications can benefit from improved heat exchanger performance.
FREMONT, CA: Engineers have to make greater sacrifices in areas such as heat management as the complexity of product design rises across practically all sectors. Managing product temperature appropriately is a challenging undertaking with many design restrictions. Engineers have attempted to circumvent these limitations for decades, but manufacturing technology has hampered their efforts. Innovative heat exchanger (HEX) designs can be created with software tools like computational fluid dynamics (CFD) and manufacturing techniques like 3D printing. Engineers can continue to explain the benefits of additive manufacturing (AM), but tangible outcomes are required for corporations to invest in the technology. Experiencing firsthand how additive manufacturing and software technologies may solve traditional thermal management issues is an effective means of gaining support. The applications below illustrate how additive manufacturing and software design enhanced thermal control:
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Fuel-Cooled Oil Coolers
In several industrial processing or power generation machines, heat exchangers cool the engine and gearbox oil. These same heat exchangers also warm cold fuel to increase combustion efficiency. Shell-and-tube oil coolers available off-the-shelf are too large or heavy for miniaturized or portable systems, imposing size and weight restrictions on engineers. To solve these limitations, engineers can build novel heat exchanger designs that maintain a consistent heat transfer area while decreasing size and mass.
As an illustration, the nTopology team designed a heat exchanger with a gyroid lattice core. Using nTopology for efficient design generation, engineers created a new geometry 80 percent lighter than the previous one. The design met ASTM quality criteria and included a heat transfer coefficient of 1.8 times greater.
Conformal Cooling
In aircraft applications, minimizing weight is a primary design priority. Auxiliary power units (APU) are compact turbine generators that generate vast amounts of power. These devices are essential for various aerospace applications, and design teams continually attempt to lower their weight. The thermal management of APUs is one of their primary limitations. The KW Micro Power team was able to work around this limitation when redesigning the APU's shell. Engineers created a new case design using additive manufacturing and nTopology's superior software. The team designed a microturbine housing with integrated cooling channels to do this. Their team accomplished this by adding a variable-thickness shell to the housing of their generator and eliminating material from regions that did not bear substantial loads. Overall, the crew decreased the generator's weight by 44 percent and its operating temperature by 33 degrees Celsius.
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Electronics Cooling
Thermal management is more important than ever in the march towards electrification. To guarantee product reliability, engineers must efficiently cool electrical components. Cold plates are an excellent heat management solution for electrical devices. However, the size of the heat exchanger remains a recurring issue that limits thermal performance. Engineers can circumvent this limitation by employing additive manufacturing. The lattice core design of a heat exchanger can be optimized using a simulation-driven technique. Computational fluid dynamics and thermal analysis aid designers in determining the correct flow routes via the channels. This modification enhances the heat transfer coefficient without increasing the heat exchanger's overall size.
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