Free-mounted cooling plate multi-objective topology optimization method towards precision machine tool heat dissipation: An experimental and numerical study

Abstract

Machining accuracy is reduced by precision machine tool thermal deformation. Currently, machine tool temperature and thermal deformation are usually controlled by optimizing original machine tool structure or using a cooling system. However, these methods are poor in generalization ability and convenience, and traditional cooling channels have shortcomings of a large flow resistance and low heat transfer efficiency. In this study, a cooling plate multi-objective topology optimization method towards precision machine tool heat dissipation is proposed. Firstly, multi-objective topology optimization model is established with maximum heat exchange and minimum fluid dissipation energy as objective function. Then effect of various design parameters on topology optimization results is investigated. Penalty factor and design Reynolds number are taken as design variables, and heat dissipation and flow performances of different topology optimization results are analyzed. Response surface model is constructed, and then an analytical model of average temperature in design domain and pressure drop generated by Pareto fronts under different working conditions are obtained. Furthermore, a full-size three-dimensional thermal-fluid interaction verification model is constructed, and cooling and flow performances of topology optimization cooling plate are compared with those of traditional spiral cooling plate. Numerical results show that cooling performance of topology optimization cooling plate is stronger than that of spiral cooling plate at high Reynolds number, and pressure drop of topology optimization cooling plate is reduced by 85.38% compared with that of spiral cooling plate. Finally, topology optimization and spiral cooling plates are manufactured, and experimental platform is built to evaluate heat dissipation and flow performances of cooling plates. For topology optimization plate, maximum deviations between simulation results and experimental data for temperature and pressure drop are 4.8% and 6.4%, respectively. The effectiveness and feasibility of the topology optimization design for cooling plate are verified.