A two-parameter model for predicting thermal contact resistance between crystal and aluminum alloy based on turning morphology

Thermal contact resistance (TCR) is a key factor in thermal engineering which affects the thermal-structural design of precision instruments. To reveal the influence of turning morphology on the TCR between potassium dihydrogen phosphate (KDP) crystal and aluminum alloy, a novel simplified model considering two parameters of wavelength and slope is proposed. Meanwhile, the TCR of KDP crystal and aluminum alloy are experimentally investigated to validate this two-parameter model, where the effects of different wavelengths and slopes on Mises stress distribution, temperature distribution, heat flux and TCR can be analyzed. By incorporating the theory of plane turning, the TCR can be reduced by controlling the feed rate and cutting thickness under a certain roughness. This research provides a theoretical basis for the thermal-structural design of crystal modules and the turning of aluminum alloy.

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