Extended CFD Study on Direct Oil Cooling for AFPM Motors: Influence of Nozzle Diameter and Axial Position

This work presents a numerical investigation of a direct oil cooling system for Axial Flux Permanent Magnet (AFPM) machines. Building upon the authors’ previous study, which established the fundamental fluid dynamic mechanisms governing oil jet impingement on curved coil surfaces, the present research extends the analysis by performing a systematic parametric optimization of nozzle diameter and axial position. A validated CFD model, benchmarked against experimental data from the literature, is employed to quantify the influence of jet momentum, stagnation pressure, and flow attachment on the resulting thermal performance. Nine configurations are simulated at constant coolant mass flow rate, revealing that the nozzle diameter is the dominant parameter: smaller diameters generate higher jet velocities, stronger stagnation regions, and larger jet-induced forces, leading to significantly enhanced heat transfer coefficients and Nusselt numbers. Nozzle height plays a secondary yet relevant role, as higher positions promote a more coherent jet core and improve impingement quality. Among the nine simulated cases, the configuration with D = 3 mm and L = 14 mm achieves the lowest hotspot temperature and the most efficient energetic behavior within the simulated set, with only a modest increase in pumping power. The results confirm that direct oil impingement is highly sensitive to jet momentum and angle of attack and demonstrate that optimized nozzle design can substantially improve the thermal management of high power density AFPM machines. This extended analysis provides quantitative references for nozzle sizing and placement within the simulated operating conditions with enhanced cooling efficiency.