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Research on the structure of perforated turbulence-inducing cooling channel based on the synergistic design of heat transfer performance and lightweight of steel pistons
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DOI：10.1016/j.csite.2026.108370.png)
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Abstract
En 中文
A perforated turbulence-inducing cooling channel is proposed to simultaneously enhance heat transfer and achieve mass reduction of steel pistons in highly boosted diesel engines. A transient coupled fluid-solid heat transfer model was developed to capture the oscillatory oil flow and spatially varying convective heat transfer within the channel. The wall heat transfer coefficients obtained from the simulations were coupled with a thermo-mechanical integrated finite element model to evaluate piston temperature and stress. The oscillatory flow and heat transfer model was calibrated through oil-oscillation visualization experiments, while the piston thermal model was validated against engine bench temperature measurements at critical positions. A multi-objective optimization framework was established by integrating optimal Latin hypercube sampling (OLHS), a genetic algorithm-optimized least-squares support vector machine (GA-LSSVM) surrogate model, and multi-objective particle swarm optimization (MOPSO). This framework was developed to achieve the coupled optimization of heat transfer enhancement and lightweight design. Compared with the original design, the optimized piston reduces mass by 166 g, decreases maximum throat temperature by 38.4 °C, and lowers peak thermal stress by 23%. The minimum fatigue safety factor reaches 1.3, satisfying reliability requirements. The results show that the proposed structure enhances near-wall flow, turbulence mixing, and oil coverage, thereby improving convective heat transfer. An effective approach is presented for the coupled optimization of thermal management and lightweight design in steel pistons.
Keywords:
Steel piston
Cooling channel
Turbulence-inducing
Heat transfer
Lightweight design
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