ToffeeX’s breakthrough in aircraft engine thermal management: Cooling the future
Electrifying aircraft engines has become a key trend as the aerospace industry adopts sustainable practices. This shift aims to reduce carbon emissions and improve energy efficiency. However, it presents significant thermal management challenges. New cooling systems for electrified aviation are essential. ToffeeX uses its advanced fluid topology optimization software to improve engine cooling systems, ensuring both efficiency and reliability.
What is fluid topology optimization?
Fluid topology optimization is a method ToffeeX uses to design optimal cooling systems for electrified aircraft engines. ToffeeX employs physics-driven generative design to deliver fluid topology optimization. Unlike traditional methods that rely on trial and error, topology optimization uses mathematical models to simulate and improve coolant system designs. This method precisely manipulates coolant paths, optimizing heat transfer efficiency while minimizing material usage and system weight. With this technology, ToffeeX users can create cooling systems for electrified aviation that outperform conventional methods in both performance and sustainability.
The fluid topology optimization process in ToffeeX—The serpentine design consists of a narrow reversing tube between the inlet and outlet, cooling the central portion of the domain. The right image shows temperature contours for a cross-section through the center of the cold plate. Both designs produce hot and cold regions but differ in their distributions.
Superior design and enhanced performance by ToffeeX
The ToffeeX platform significantly improves conventional cooling designs using physics-driven generative design. In a benchmark study on aircraft engines, our optimized cold plate design reduced mass by 38.5% and pressure drop by 65% compared to traditional serpentine cooling systems. These benefits arise from fluid topology optimization’s ability to finely tune cooling paths, ensuring efficient heat removal without excess bulk. Such advancements enhance aircraft performance and significantly reduce environmental impact.
Pressure distribution in Pascals for the serpentine case (top) and the optimized case (bottom). Note that the scale for the optimized case has been cropped for clarity to remove the static point at the splitter. The peak in this region was 6.1kPa, which distorted the contour plot.
Leveraging advanced manufacturing: Additive manufacturing and milling
Advanced manufacturing techniques such as additive manufacturing (3D printing) and precision milling are employed to realize the complex geometries designed with the ToffeeX platform. These methods produce intricate features and internal channels that traditional processes can’t achieve. This adaptability allows seamless integration with existing aircraft engine components, optimizing performance while maintaining structural integrity.
Real-world application – Fluid topology
optimization for the thermal management of electric parts in aircraft engines
A compelling illustration of ToffeeX’s impact is a project optimizing an aircraft engine’s cooling system. This effort was part of a larger initiative to enhance the efficiency and performance of electrified aircraft engines. These engines are crucial for the aviation industry’s shift towards sustainable technologies.
Challenge and objectives
The primary challenge was to improve an aircraft engine’s cooling efficiency without changing its external dimensions or power output. This requirement ensured the new cooling system could integrate into existing aircraft models without significant design or aerodynamic modifications.
ToffeeX’s approach
Using advanced fluid topology optimization, ToffeeX tackled this challenge by redesigning the engine’s coolant system. The goal was to maximize heat dissipation while minimizing system weight and ensuring seamless integration into the engine’s existing architecture. This involved iterative simulations and adjustments, evaluating each design variant for thermal performance, pressure drop, and structural integrity.
Design features
The optimized coolant system featured several innovative design elements tailored to meet the specific thermal management needs of the aircraft engine. These included:
- Complex flow pathways: Unlike traditional designs with simple, straight channels, the optimized design used complex flow pathways. These pathways strategically directed coolant to the hottest parts of the engine, ensuring more efficient heat absorption and dissipation.
- Reduced material use: Using fluid topology optimization, ToffeeX reduced the material used in the coolant system. This reduced the system’s weight by 38.5% and contributed to the engine’s overall efficiency by reducing its load.
- Enhanced cooling efficiency: The new design improved cooling efficiency by optimizing coolant flow through the engine. This was achieved by minimizing obstructions and optimizing channel cross-sectional areas to enhance flow rate and heat transfer capabilities.
Manufacturing and integration
To realize this intricate design, ToffeeX leveraged state-of-the-art additive manufacturing techniques. Consequently, these techniques allowed for the precise fabrication of complex internal geometries that traditional methods could not achieve. Metal 3D printing was particularly beneficial in producing lightweight, high-strength components that met the rigorous aerospace engineering standards.
Results and impact
The redesigned coolant system underwent rigorous testing to evaluate its performance under various operational conditions. The results were highly promising, demonstrating significant thermal management improvements without compromising engine performance. Furthermore, the cooling system effectively maintained optimal operating temperatures, even under high loads, enhancing the engine’s reliability and safety.
The success of this project not only showcased the ToffeeX platform’s capabilities but also marked a significant step forward in adopting advanced cooling technologies in the aerospace industry. ToffeeX helped pave the way for more fuel-efficient and environmentally friendly aircraft designs by substantially reducing system weight and enhancing thermal efficiency.
This real-world application underscores ToffeeX’s commitment to innovation and its role in driving the aerospace industry toward a sustainable future. With each project, ToffeeX continues to demonstrate that advanced thermal management solutions are crucial for developing next-generation aircraft engines.
Conclusion
As the aerospace sector moves toward electrification, ToffeeX leads the way with state-of-the-art solutions addressing the critical challenge of effective cooling systems for electrified aviation. Our innovative use of fluid topology optimization, which leverages physics-driven generative design, enhances aircraft engine performance and efficiency while supporting the industry’s shift toward sustainable aviation practices. With ToffeeX, the future of aviation cooling goes beyond maintaining temperatures to pushing the boundaries of what’s possible in thermal management for the aerospace industry.
