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

摘要： 研究旨在解决新能源汽车、储能和特种车辆等行业的电池包液冷系统开发中仿真周期 长和硬件成本高的行业痛点，提出一种基于等效粗糙度的计算流体动力学（CFD）仿真的简 化方法。通过建立含双直角弯头的三维波纹管模型，并采用仿真软件 Fluent 中的切应力输运 （SST）k-ω 湍流模型分析不同流速下的压降特性。以进口速度 1.5 m/s 为标定的基准速度， 分析进口速度 0.5～2.5 m/s 范围内等效简化方法的精确度。研究表明，全域等效法最大偏差 为 15.47%；分区标定法通过划分 5 个特征区域并设置梯度粗糙度参数，最大误差 7.18%。等 效光滑管的简化方法将波纹管的 1 116 万网格降至 15.8 万，极大地降低了网格量，提高了计 算速度，为大型液冷系统仿真提供有效解决方案。

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