Heat dissipation is considered as a challenging task in the manufacturing field. The main objective of this study is to design a new pressure wheel assembly of a laser weld system to maximize heat dissipation in order to endorse a better performance of the wheel and help achieve a long lasting cycle of life. In this study transient thermal and structural analysis of the pressure wheel is conducted by using ANSYS workbench. The work will examine the effects of geometrical parameters on the thermal performance of pressure wheel assembly during a period of time. Different design models and numerical simulations are performed in investigating the effects of geometrical holes and ventilated discs on the disk on the thermal performance, which include the shape, size, and distribution of pillar posts. The analysis will support the design process in monitoring different models in terms of performance, heat loss and manufacturing cost.

A comparison is made for three different designs and the best design is selected. The calculated results estimated in a period of time of 50 seconds show that the temperature drops with the 3rd design from T = 500 K to 453 K. Also under giving limitations the design with enhanced heat transfer has a better heat dissipation and the temperature decreases to T = 399 K. The present work will help improve the performance of pressure wheel in the welding industry by providing computational results for successive design testing and data validation.

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