关键词: 波纹管；CFD 仿真；全域等效法；分区标定法；等效粗糙度；压降

Abstract: The aim of this study is to address the industry pain points of long simulation cycles and high hardware costs in the development of battery packs liquid cooling systems for industries such as new energy vehicles, energy storage industry, and special vehicles. A simplified method of computational fluid dynamics (CFD) simulation based on equivalent roughness is proposed. A threedimensional corrugated tube model with double right-angle elbows is established, and the pressure drop characteristics under different flow velocities are analyzed using the shear-stress transport (SST) k-ω turbulence model. With an inlet velocity of 1.5 m/s as the calibration benchmark, the accuracy of equivalent simplification methods is evaluated within the velocity range of 0.5 m/s to 2.5 m/s. The results demonstrate that the global equivalence method exhibits a maximum deviation of 15.47%, while the zonal calibration method with 5 characteristic regions and gradient roughness parameters achieves a maximum error of 7.18%. The simplified equivalent smooth tube model reduces mesh count from 1.116×107 to 1.58×105 , significantly decreasing computational load and improving simulation speed, providing an effective solution for large-scale liquid cooling system simulations.

Key words: corrugated tube; CFD simulation; global equivalence method; regional calibration method; equivalent roughness; pressure drop