Aerodynamic shape optimization of an electric aircraft motor surface heat exchanger with conjugate heat transfer constraint

• An adjoint-based shape optimization method minimized the drag of a surface heat exchanger for an array transfer constraint values. Optimal geometry changed from smooth to finned as load increased. The designs optimized using conjugate model were smaller than those with convection-only model. fins designed by optimizer had forward tilt reduce aft adverse-pressure gradient and consequently separation. Electrified aircraft benefit versatile ways electric motors can be integrated airframe. However, thermal management is needed move waste out because not expelled exhaust in conventional engine. Plate-fin, fin, exchangers are incorporated air-side electrified systems. Typically, analytic tools used design within these categories. lack fidelity required detailed shaping assessment general configurations. Tools based on first principles, such finite element analysis or computational fluid dynamics, verify performance but too costly use manual loop. Shape first-principles-based models without limiting previously well studied. In this work, we apply methodology sink high-lift motor technology demonstrator, X-57 Maxwell. We gradient-based modify thickness distribution find that minimize while meeting constraint. To motor, both compare resulting differences shapes. found under-predicted rejection thus led larger necessary sinks when optimization. study effect design, baseline less efficient motors. Our results show how exchanger’s changes uniformly thick increases. Furthermore, variation across driven pressure due flow Finally, conclude comparison representing more simple fin have shifted adverse gradient, which mitigates separation part fin. developed could also applied improve other exchangers, specifically reject relatively low amounts heat.