OBJECTIVE OF CONDUCTING THE CFD ANALYSIS
The client is a global medical device OEM, one of the fastest growing in this segment. The client has approached us with the existing design of the high-voltage X-ray tank unit. The client is interested in understanding the heat transfer phenomena for the complete system, which enables him to make conscious engineering decisions to enhance the performance of the device. Our CFD model is validated with the experimental results. CFD model is finetuned in all possible aspects, and we ensured that it represents the actual physical phenomena. All the heat transfer paths are analyzed, and the heat balance sheet has enabled our client to take well-informed engineering designs.
CFD ANALYSIS APPROACH
The computational domain is discretized using a poly-hexcore mesh comprising approximately 3 million cells to achieve a balance between computational efficiency and solution accuracy. The transformer units and PCB assembly are represented as equivalent thermal blocks with appropriate material properties and heat generation rates. The X-ray tube is modelled in greater detail, including key components such as the cathode, anode, filament, and focal point, with suitable material properties and thermal boundary conditions to accurately represent heat generation and dissipation. A transient CFD analysis is performed over a total duration of 16 minutes to capture the time-dependent thermal behaviour of the system. The transformer oil is modelled by accounting for buoyancy-driven natural convection, enabling the prediction of fluid circulation and heat transfer within the tank. Intermediate CFD results are evaluated at different time intervals to track temperature evolution, identify potential hot spots, and understand the transient heat transfer characteristics of the high-voltage X-ray tank assembly.
CFD ANALYSIS RESULTS
The CFD simulation achieved smooth and stable convergence, demonstrating the suitability of the mesh quality and time step settings adopted for the transient analysis. Post processing focused on evaluating the thermal behaviour of the system through temperature distribution, temperature variation over time, and heat flux across critical components and interfaces. The intermediate simulation results were analysed to understand the evolution of heat transfer, identify potential hot spots, and assess the overall thermal performance of the high voltage X ray tank assembly. The final deliverables included a comprehensive CFD analysis report documenting the simulation methodology, boundary conditions, and key thermal findings, along with transient animation videos illustrating the thermal behaviour of the complete system at multiple time intervals, as specified by the customer.
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