- ISSN 0258-2724
- CN 51-1277/U
- EI Compendex
- Scopus
- Indexed by Core Journals of China, Chinese S&T Journal Citation Reports
- Chinese S&T Journal Citation Reports
- Chinese Science Citation Database
| Citation: | ZHAO Haining, WANG Tonghai, ZHAO Chuan, XU Fangchao, YANG Wenhua, LI Bo, LIANG Zhongwei, SUN Feng. Air-Gap Windage Loss in High-Speed Motorized Spindles Based on Computational Fluid Dynamics[J]. Journal of Southwest Jiaotong University. doi: 10.3969/j.issn.0258-2724.20250548
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To address the design challenges of heat dissipation and energy efficiency caused by air friction loss in the air gap of high-speed permanent magnet motorized spindles, the formation mechanism of windage loss and the evolution laws of vortex flow under the coupled effect of stator slots and axial ventilation cooling were revealed. First, an ideal air-gap model with smooth walls and a realistic air-gap model containing 18 stator slots were established, respectively. Second, the independent impact of stator slots was quantitatively evaluated by comparing the energy dissipation differences between the two air-gap models under the condition of no axial ventilation. Finally, the nonlinear regulation effect of ventilation intensity on the internal flow field structure and energy dissipation characteristics of the air gap was systematically evaluated by applying axial cooling airflows at different velocities. The results indicate: 1) stator slots are the decisive factor leading to the surge of windage loss. Compared with the ideal air gap with smooth walls, the increase in additional loss caused by stator slots is nearly 80%. 2) In the air gap containing stator slots, the regulation of loss by axial ventilation exhibits significant non-monotonic and multi-stage characteristics: After weak axial ventilation is introduced, the loss decreases to the minimum at 2.00 m/s, with a decrease of more than 19%; when the flow velocity enters the critical range of 6.00–10.00 m/s, the flow field instability leads to a sharp surge in energy dissipation by over 26%; when the flow velocity exceeds 10.00 m/s, the vortex suppression effect dominates the flow field to restore stability, and the energy dissipation shows a steady and monotonic increasing trend after a sudden drop.
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