Synergistic thermo-hydraulic performance of hybrid winged–wavy rib and dimpled cooling channels for EV battery thermal management

Information from the abstract

This study presents a numerical investigation of the thermo-hydraulic performance of a hybrid winged–wavy rib and dimpled cooling channel for electric vehicle (EV) battery thermal management under the Reynolds number range of 10,000–50,000. This study focuses on the unresolved interaction between longitudinal vortices generated by the wings and recirculation induced by dimples, which has not been systematically measured in prior hybrid cooling-channel studies. The influence of wing inclination angle on flow structure, vortex dynamics, heat transfer characteristics, and pressure loss is analyzed. The results showed that integrating winged ribs with wavy geometries and dimples generated strong longitudinal vortices and secondary flows, thereby enhancing near-wall mixing and disrupting the thermal boundary layer. As the wing inclination angle decreased from 90° to 30°, both the intensity and spatial extent of the vortical structures increased significantly. The 30° configuration produced the strongest vortex–dimple interaction, yielding local Nusselt number ratios ( Nu/Nu o ) of approximately 4.0–4.5, while the area-averaged Nusselt number was enhanced by up to 36.2% compared to the wavy-rib baseline configuration. This improvement was accompanied by an increase in the friction factor of approximately 61.9%, indicating a notable hydraulic penalty associated with intensified flow disturbance. Despite the increase in pressure loss, the 30° configuration demonstrated the highest thermo-hydraulic performance among the investigated cases, achieving a thermal performance factor approximately 12.1% higher than that of the wavy-rib baseline. These findings highlight the critical role of vortex–recirculation coupling in heat transfer enhancement and provide useful design guidance for compact air-cooled battery thermal management systems.

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Related topics: Heat Transfer Mechanisms · Aerodynamics and Fluid Dynamics Research · Nanofluid Flow and Heat Transfer