Beruflich Dokumente
Kultur Dokumente
2009-01-0859
automate the design synthesis by altering variable number, vane angle and vane offset, GAMBIT generates
values in a search to optimize performance criteria, various mesh files for CFD and other numerical
subject to constraints. Due to the complexity of the CFD simulations.
model of brake discs, even a single iteration of the
optimization may take a large amount of time. However, FLUENT is an effective CFD solver, which is used to
if these optimizations are implemented in a massively- simulate the complex turbulent air flow inside the rotor
parallel computer system, the computation time could passages.
easily be reduced approximately by a factor equal to the
total number of slave computers. iSIGHT can enable the rapid integration of commercial
CAD/CAE software, internally developed programs, and
To explore the potential of an automated design Excel spreadsheets and automate their execution to
synthesis process of brake discs, in the current paper, accelerate the evaluation of many more design
an integrated design synthesis has been proposed and alternatives. In addition, it provides leading edge design
implemented. Commercial software GAMBIT is used for exploration and optimization technology to ensure that
geometrical modeling and automatic mesh generation an optimal design is discovered using techniques such
for vented discs. Then, the CFD package, FLUENT [9], as optimization, approximations and design of
is employed to simulate the air flow through the vented experiment (DOE) [10].
disc. To automate the design process of the disc rotor, a
software framework, iSIGHT [10], is used to integrate the As an integration and optimization tool, iSIGHT can
geometrical modeling using GAMBIT and numerical integrate GAMBIT and FLUENT, leading to optimal
simulations based on FLUENT. Through this integrated design parameters. With a given set of input parameters,
design synthesis process, the disc rotor geometrical such as the inner radius, outer radius, vane number,
shape optimization is performed with design of vane angle, vane offset, and rotor thickness, from
experiments (DOE) studies. The main design criterion of iSIGHT, GAMBIT will build geometrical models and
the geometrical optimization is to maximize the generate corresponding mesh files. Then, FLUENT will
convective cooling by increasing the heat transfer rate call these meshing files to calculate specified
inside the rotor passages. performance indices, such as heat transfer rates. The
resulting performance indices will be returned to iSIGHT.
Through objective fitness evaluations, iSIGHT will
GEOMETRICAL OPTIMIZATION FRAMEWORK coordinate the trade-off relations among various design
criteria and constraints and identify a set of better design
The geometrical optimization was implemented by variables. The resulting design variable set will be
integrating geometrical modeling and CFD numerical forwarded to GAMBIT as the new input parameters for
simulations. The framework for automated design the next iteration. The above procedure will repeat until
synthesis is depicted in figure 1. This framework consists an optimal set of design variables is obtained [1].
of the following three software packages: GAMBIT,
FLUENT and ISIGHT. NUMERICAL SIMULATIONS WITH CFD
Inner radius In order to achieve accurate results, in the current study
Outer radius Objective:
Vane number Maximize the heat Net heat
a 3-D disc rotor model has been generated and the
Angel of vanes transfer rate transfer rate corresponding numerical simulations with CFD have
Vane offset Strategy: DOE been conducted. Figure 2 schematically shows the 3-D
Thickness disc rotor model.
Mesh file
GAMBIT FLUENT
In the numerical simulations and design optimization, the figure 6. Since the vanes are evenly arranged along the
design variables include the rotor thickness (RT), inner whole disc rotor, a given vane number corresponds to a
radius (IR), outer radius (OR), vane number (VNu), vane specified section angle. The vane number can be
angle (VA), and vane offset (VO). The design variables changed by varying the section angles. When changing
RT, IR and OR are defined geometrically in figure 2. the vane number, the vane thickness remains constant.
Note that the rotor thickness is the total distance
between the two disc brake surfaces that touch braking
pads. When rotor thickness changes, the brake plate
thickness remains constant and the cooling passage
width varies accordingly. VA is defined as the angle
between the axis of a vane and the corresponding radial
line in the rotor plane, which is perpendicular to the
rotating axis of the rotor. If the rotor is rotating clockwise
and the axis of the vane is oriented counterclockwise
with respect to the corresponding radial line, the vane
angle has a positive sense. As shown in figure 3, the
vanes in the left and right take the vane angle with the
o o
values of +10 and +30 , respectively. VO is used as a
measurement for the curvature of a curved vane. As
shown in figure 4, it is defined as the offset of the middle
point of the curved vane from its straight vane
counterpart, assuming that the two ends of the former
coincide with those of the latter. Figure 5 shows two Figure 5: Representation of vanes with the offsets of 1
curved vanes with different offsets. With the introduction (left) and 3 mm (right) [1]
of the periodic side boundary conditions, the whole disc
The 3-D mesh model was constructed with GAMBIT.
rotor can be modeled as a partial section, as shown in
Due to the axial symmetric of the rotor, a partial cooling
passage was generated with boundary conditions
applied on both sides, as shown in figures 6, 7 and 8.
Figure 4: Geometrical definition of the offset of a curved Figure 7: Outlet section of a 3-D section produced by
vane GAMBIT
variables steps
VNu 32 36 40 44 48 52
56 60 64 68 72
VA (degree) 0 10 20 30
VO (mm) 0 1 2 3
IR (mm) 68 72 76 80 84
OR (mm) 127 134 141 148 151
RT (mm) 18 19 20 21 22
VNu: 56
IR: 83.6 mm
OR: 155.1 mm
VA: 0°
VO: 02 mm
RT: 22 mm
7000
6000
Figure 15: Vane offset and vane angle vs. heat transfer
rate for 40 vanes
5000
32 36 40 44 48 52 56 60 64 68 72
Vane Numbers
300000
250000
Total heat(W)
200000
150000
100000
24 28 32 36 40 44 48 52 56 60 64 68 72 76
Vane numbers
Figure 22: Vane angle and vane offset vs. total heat
160000 transfer rate with 56 vanes (2-D models) [1]
Total heat transfer rate (KW)
140000
As for the vane offset and vane angle, the numerical
simulations based on the 2-D and 3- D models give a
120000
similar result, that is, the heat transfer rate reaches a
maximum value when the vane angle has a value within
100000 the range of 0° - 20°, whereas for the vane offset, there
68.4 72.2 76 79.8 83.6 is no deterministic relation with the heat transfer rate, as
shown in figures 15 and 22.
Inner radius (mm)
220000
Therefore, the 3-D models are more realistic and have
higher fidelity, which can give more accurate results, but
190000 using 2-D models can drastically reduce the computing
time.
160000
CONCLUSION
130000
This paper presented an automated design synthesis
126.9 134 141 148 155.1 approach to the geometrical optimization of vented brake
Outer radius (mm) discs of automotive vehicles. The design optimization
was implemented using a software framework, iSIGHT,
to integrate the geometric modeling by a commercial
Figure 21: Outer radius vs. total heat transfer rate [1] software package, GAMBIT, and numerical simulations
based on a computational fluid dynamics tool, FLUENT.
The effectiveness of the automated design synthesis
surface area gives better cooling performance. However, approach was investigated through optimizing the
in the more realistic 3-D model, when the inner radius of geometrical parameters of a 3-D model of a vented
the rotor decreases, the entrance area decreases as brake disc with a Design of Experiments (DOE)
well, which blocks the inlet air flow. As shown in both technique. It is expected that this automated design
figures 14 and 21, for both the 2-D and 3-D models, synthesis approach can be extended to the optimization
increasing the outer radius of the rotor will result in of realistic 3-D models of vented brake discs using
higher heat transfer rate. typical optimization techniques, such as genetic
algorithms and gradient based search methods.
variables affecting brake disc thermal performance. 8. Michael D. Hudson and Roland L. Ruhl, Ventilated
These design variables are vane numbers, inner and Brake Rotor Air Flow Investigation, SAE
outer radius, and rotor thickness. With the DOE studies International Congress & Exposition, Detroit,
implemented through the automated design synthesis Michigan, February 24-27, 1997.
approach, the thermal performance of brake rotors is 9. http://www.fluent.com/software/gambit/index.htm.
greatly improved by optimizing the geometric design 10. http://www.engineous.com/iSIGHT.cfm.
variables.
ACKNOWLEDGMENTS
REFERENCES