Proceedings of ICOMAST2006 International Conference on Manufacturing Science and Technology August 28-30, 2006, Melaka, Malaysia

493 3-D HEAT, FLUID FLOW AND THERMAL STRESS ANALYSIS IN A LINEAR MOTOR WITH A WATER-COOLING CHANNEL P. Y. Chen, C. H. Chien, J. Y. Jang
Department of Mechanical Engineering, National Cheng-Kung University, Tainan, Taiwan 70101 E-mail: jangjim@mail.ncku.edu.tw

ABSTRACT Linear motor has high speed, high acceleration, high feed speed, lower noise, high accuracy, and superior velocity control compared to a conventional ball-screw motor. However, the increase of the high speed also incurs adverse effects such as the heat generation of the motor system. This also results in thermal stress in the system. Therefore, how to solve the thermal behavior in a linear motor is becoming a very important topic. The purpose of this paper is to numerically analyze the three-dimensional heat transfer and thermal stress in a linear motor with water-cooling module. The water-cooling module is made by aluminum with copper pipe inside, and the water was pumped into the module to cool down the linear motor. The effects of different heat sources (q = 11, 46, 71 W/m2,) and cooling water flow rate (0.5 m/s and 1.0 m/s) on the temperature distribution and thermal stress are examined in detail Keywords: Linear motor; Water-cooling channel; Heat transfer analysis; Thermal stress 1. INTRODUCTION The linear motor, which has convention of high transitional speed, high acceleration, high precision position, high control performance, lower noise and wear, was widely used in lot of high precision machine tools and semiconductor equipments. However, the heat generation caused by coil s power lose of linear motor leads to thermal stress, thermal deformation and affects the precision of machining and position. Therefore, the cooling problem of linear motor is becoming a very important topic. A number of studies have been published on thermal behavior of linear motor. Bossmanns and Tu [1] presented a power flow model for a more complete thermo-mechanical model of highspeed motorized spindles by using finite difference method. Burnett [2] developed a two-dimensional thermal model for high-speed motorized spindles by using thermal resistance method. Takeuti and Tanigawa [3] indicated that ball bearings, electric motor and oil pressure cylinder of gear box were the major heat sources that affected the temperature rise and thermal deformation. Zienkiewicz [4] analyzed the steady-state thermal heat transfer of spindle motor with two-dimensional finite element method. Zhou and Goodwill [5] presented a twodimensional finite element model to analyze the velocity in the hollow water bend channel with uniform cross-section area, and confirmed the results by experiment. The biggest part of heat generation of linear motor comes from the copper coil surrounding the stator sheet steel, and large electrical current is going to cause more heat generation and temperature rise. In this paper a linear motor shown in Fig. 1 is numerically evaluated in detail by different electrical current (4 A, 8 A, 10 A) and cooling-water flow rate (3.8 l/min, 7.6 l/min). It is noted that for a electrical current is 4 A, 8 A and 10 A, the heat flux q is 11 W/cm2, 46 W/cm2 and 71 W/cm2), respectively. The water-cooling channel is made up of an aluminum module with a 4-pass and 12.7 mm diameter circular copper pipe inside. The water velocity is 0.5 m/s and 1.0 m/s as the flow rate is 3.8 l/min and 7.6 l/min, respectively. Inlet temperature of water used to cool down the linear motor is 25oC. Temperature rise, thermal stress and deformation are examined by adjusting the different electrical current and cooling-water velocity. 2. MATHEMATICAL ANALYSIS A linear motor with 4-pass circular water-cooling channel inside is investigated in this paper. The physical model and outside dimensions are schematically illustrated in Fig.1 and Fig. 2. Table 1 lists the thermal conductivities of material. 2.1. Heat transfer governing equations Heat transfers by thermal conduction within solid area of the linear motor, and by thermal convection on the interface of cooling-water channel. The heat caused from coil can be removed by cooling water and lead to temperature gradient. This is so called the thermal conjugated problem. The thermal conduction equation on solid area can be simplified as follows: (1) 2T
x j
2

=0

And the continuity equation, momentum equation and energy equation are presented in tensor form as follows: (2) ui =0 xi (3) u u j p (u i u j ) = [ eff ( i + ) u i ' u j '] + x j xi x j x j xi (4) p p' T + uj' + c p (u j T ) = u j (k c p u j 'T' ) x j x j x j x j x j Where u ' u ' is so called Reynolds stress term, and u 'T ' is i j j Reynolds heat flux. The general equation used to predict the turbulent model is - model developed by Launder and Spalding [6], where is the turbulent kinetic energy and is the turbulent energy dissipation rate. In this paper the extended - model presented by Chen and Kim [7] is used to simulate the flow field because it has higher precision in thermal calculation with complicated geometry [8]. Extended - equation is as follows: (5) eff k ( u jk ) = ( ) + ( Pr ) x j k x j x j (6) eff P ( u j ) = ( ) + [( c1 + c3 r ) Pr c2 ] x j x j k x j where (7) u u u j 2 2 Pr = t [2( i ) 2 + ( i + ) ( u i ) 2 ] x x x 3 i j i (8) =+
eff t

c=0.09, c1=1.15, c2=1.90, c3=0.25, k=0.75, =1.15

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Proceedings of ICOMAST2006 International Conference on Manufacturing Science and Technology August 28-30, 2006, Melaka, Malaysia Pr is turbulent kinetic energy production rate, t is turbulence viscosity, k is Prandtl number for turbulent kinetic energy and is Prandtl number for turbulent energy dissipation rate. 2.2. Wall function More dense and fine element mesh should be used to solve the sub-layer of turbulences boundary layer because of the large gradient of velocity and is not suitable for evaluating the three-dimensional flow field, but it takes a lot of compute time to simulate the problem. In this paper the wall function developed by Liakopoulos [9] is used to present the velocity field of the sub-layer in turbulences boundary layer.
u + = ln[ ( y + + 11) 4.02 (y
+2

Where 1 , 2 , 3 are the three principle stress of material.

3. NUMERICAL METHODS Fig. 4 shows the mesh used in this investigation, and the total number of grid points is approximately 182,000. The temperature field is solved numerically by STAR CD program [10], and the stress filed is simulated by using NASTRAN program [11]. 4. RESULTS AND DISCUSSIONS Fig. 5 shows the temperature distribution for stator sheet steel of linear motor under different electrical current, and Fig. 6 presents the temperature distribution for the frontal, central and rear section of stator sheet steel when the electrical current is 10 A (q = 71 W/cm2). It is noted that the maximum temperature rise of linear motor is 19.4oC and 30.4oC when the current increases from 8 to 10 A. The hot spots causes on the coil region of motor, and whole temperature rise of stator sheet steel is under 5oC as the electrical current is 4 A (q = 11 W/cm2). It is shown that the heat generation can be effectively removed by cooling water. In addition, the profile of temperature distribution for linear motor is almost the same when the cooling-water inlet velocity is 1.0 m/s (water flow rate = 7.6 l/min) and 0.5 m/s (water flow rate = 3.8 l/min). The temperature rise that occurs on the central section of stator sheet steel is higher than frontal and rear section. The maximum temperature rise reduces with the inlet velocity increasing from 0.5 m/s to 1.0 m/s, and increases from 17.4oC to 27.2oC with the electrical current increasing from 8A to 10A. Table 2 indicates the largest temperature rise with different electrical current. Temperature rise is still high (27.2oC) with the double velocity of cooling-water when linear motor working in 10A. Pressure drop under the different flow velocity and electrical current is shown in Table 3. The pressure drop between inlet and outlet of water channel increases about 3 times (from 0.01 bar to 0.03 bar) as the water flow velocity raises from 0.5m/s to 1.0m/s. It is demonstrated that more power is needed to pump the cooling-water in channel. Thermal stress and deformation are illustrated in Fig. 7. The maximum thermal stress and deformation is 17.03 Mpa and 0.0264 mm when cooling-water inlet velocity is 0.5 m/s. They reduce to 13.84 Mpa and 0.0212 mm when the water velocity increases to 1.0 m/s. Table 4 shows the maximum thermal stress and deformation when the velocity of cooling-water is 0.5 m/s and 1.0 m/s, respectively. The results show that the thermal stress and deformation have direct ratios with temperature rise, and just slightly decrease with double water inlet velocity. 5. CONCLUSIONS In this paper a linear motor with 4-pass circular water-cooling channel was investigated numerically under the different electrical current (4,8 and 10 A) and velocity of cooling-water (0.5 m/s and 1.0 m/s). The results indicate that the temperature rise of linear motor can be controlled effectively under 5oC when the electrical current is 4 A and the velocity of cooling-water is 0.5 m/s (3.8 l/min) with 25oC inlet temperature. It can be shown that the present cooling-water channel design is a very efficient heat sink. The temperature rise increases up to 30.4oC as the electrical current raises from 4 A to 10 A, and dont decrease a lot with doubling the cooling-water velocity. If the linear motor operates on more than 4 A electrical current and the temperature rise wants to be controlled under 5oC, some other cooling design is needed such as changing the dimension and arrangement of cooling-water channel, using the material with more higher thermal conductivity, or using the cooling fan to remove the heat generation.

7.37 y + + 83.3) 0.79

] + 5.63 tan 1 (0.12 y + 0.441) 3.81

(9) where

u y , y+ = u = w

y+ should bigger than 11.63.

2.3. Boundary conditions 2.3.1 Entrance boundary condition: It is assumed that entrance region is the length with 5 times the diameter of channel extended from inlet, and the inlet velocity is uniform flow with equal temperature. Tin = 25oC when uin =0.5 and 1.0m/sec C k 3/ 2 2 k = (I u in ) = 0.05d Where Tin is the inlet temperature and uin is the inlet velocity, I = u' / u is turbulent intensity and is about 10%, d is the diameter of channel. 2.3.2 Solid-liquid interface: Consider the energy balance on the interface of solid-liquid: T fluid T (10) k fluid = k solid solid n n Tfluid = Tsolid 2.4. Stress governing equations The thermal stress of linear motor is lead by the thermal expansion caused by temperature gradient and material with different thermal conductivity, the stress-strain equation for the linear motor becomes as follows: (11) { } = { el } + { th }

Where { el } is elastic-strain term and { th } is thermal-strain term. The elastic-strain term can be presented as follows: (12) { el } = [ D ] 1{ } 1 Where [ D ] is the inverse of elastic matrix. Assume that the material has isotropic property, the thermal strain term can be presented as follows: (13) { th } = T Where is the thermal expansion coefficient of material. Substituting equation (13) and (12) into equation (11), the total strain correlation becomes as follows: (14) { } = [ D ] 1{ } + T

x =
y =
z =

x
y
z
E

( y + z ) + T
( x + z ) + T

(15) (16) (17) (18)

( x + y ) + T E E The Von-Mises stresses is defined as follow:

E =
1 [( 1 2 ) 2 + ( 2 3 ) 2 + ( 3 1 ) 2 ] 2

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Proceedings of ICOMAST2006 International Conference on Manufacturing Science and Technology August 28-30, 2006, Melaka, Malaysia REFERENCES

[1] Bossmanns, B. and Tu, J. F., A thermal model for high speed motorized spindles , International Journal of Machine Tools and Manufacture 39, pp.1345-1366, 1999 [2] Burnett, D. S., Finite Element Analysis from Concepts to Applications , Addison-Wesley Publishing Company, 1987 [3] Takeuti, Y. and Tanigawa, Y., A New Numerical Method for Transient Thermal Stress Problem , International Journal for Numerical Methods in Engineering, Vol. 14,pp.987-1000, Jul. 1978 [4] Zienkiewicz, O. C. and Cheung, Y.K., Finite Element in The Solution of Field Problems , The Engineer, 220, 1965,pp.507-510. [5] Zhou, J. G. and Goodwill, I. M., A Finite Volume for Steady State 2D shallow Water Flows, Int. J. Num.Meth. in Eng, Vol 7 ,1997,pp.4-23 [6] Launder, B. E., and Spalding, A.D. Mathematical Models of Turbulence, pp. 90-100, Academic, London.,1972 [7] Chen, Y. S., and Kim, S.W., Computation of Turbulent Flows Using an Extended k Turbulence Closure Model , NASA CR-179204, 1987, Oct [8] Wang, T. S., and Chen, Y. S., Unified Navier-Stokes flowfield and performance analysis of liquid rocket engines , AIAA Journal, Vol. 9, No. 5, pp. 678-685.,1993. [9] Liakopoulos, A., Explicit Representations of the Complete Velocity Profile in a Turbulent Boundary Layer. AIAA Journal, Vol. 22, pp. 844-846., 1984. [10] STAR CD V.3.15.A, Simulation of Turbulent Flow in Arbitrary Regions, Computational Dynamics Limited, UK, 2003 [11] Nastran for Windows 4.0 users manual, 1998.
Table 1. Thermal conductivity for linear motor Stator sheet Material Aluminum Steel steel Thermal 204 59 42 conductivity (W/m-oC) Table 2. Maximum temperature rise under different I and V

(a) Assembly of linear motor

(b) Stator sheet steel Fig. 1. Outline of linear motor Aluminum Steel Stator sheet steel

Water-in channel

Bolts hole

Water-out channel Fig. 2. The physical model of the linear motor

12.7 r

Water velocity V (m/s)

V = 0.5 V = 1.0

4.8 oC 4.3 oC

19.4 oC 17.4 oC

30.4 oC 27.2 oC
25

50

Electrical current I

4A (q = 11 W/cm2)

8A (q = 46 W/cm2)

10 A (q = 71 W/cm2)

25

26

12

30

12

26

Table 3. Temperature rise and pressure drop under V and I 8A 10 A Water 4A Pressure velocity (q = 46 (q = 71 (q = 11 drop (bar) (m/s) W/cm2) W/cm2) W/cm2)

Fig. 3.. Dimension of linear motor (unit : mm)

V = 0.5 V = 1.0

0.01 0.03

0.6 C 0.3 C
o

2.3 C 1.2 C
o

3.6 C 1.8 oC

Table 4. Maximuml stress and deformation under different V Water Maximum thermal Maximum velocity stress (MPa) deformation (mm)

V = 0.5 m/s V = 1.0 m/s

17.03 13.84

0.0264 0.0212
Fig. 4.. Finite element mesh

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Proceedings of ICOMAST2006 International Conference on Manufacturing Science and Technology August 28-30, 2006, Melaka, Malaysia

I=10A, (q = 71 W/cm2)

Stress distribution when water is 0.5 m/s.

I=8A, (q = 46 W/cm2) Deformation when water is 0.5 m/s.

I=4A, (q = 11 W/cm2) Fig. 5. Temperature distribution for water velocity 0.5m/s with different current. Rear section Stress distribution when water is 1.0 m/s.

Front section

Central section Deformation when water is 1.0 m/s.

Fig. 7. Temperature distribution when water velocity

Front section

Central section

Rear section

Fig. 6.. Temperature distribution as water velocity is 0.5 m/s and electric current is 10 A (q = 71 W/cm2).

220