In order to systematically deepen the understanding of heat transfer enhancement mechanisms and to address the theoretical gap between secondary flow and field synergy, this study aims to uncover the relationships and interaction mechanisms between secondary flow, field synergy effects, geometric structures, and heat transfer characteristics. Based on helical groove tubes in gas-phase rotary shell-and-tube heat exchangers, with helical ribs enhancing heat transfer as the core focus, computational fluid dynamics (CFD) simulations are employed to qualitatively and quantitatively analyze the complex relationships between secondary flow intensity, geometric parameters, the heat transfer-field synergy number , and the flow resistance-field synergy number . A “multi-scale flow-heat synergy” framework, integrating both microscopic and macroscopic levels, is established. The study reveals that the dominant mechanism of convective heat transfer within the tube is as follows: secondary flow reshapes the radial and tangential velocity components within the flow field, broadening the lateral transport paths for momentum and heat, thereby disrupting the singular mode of thermal diffusion. As a critical link between geometry, motion parameters, heat transfer, and flow resistance synergy, the variation in secondary flow intensity exposes the inherent contradiction that “heat transfer synergy optimization is invariably accompanied by flow resistance synergy degradation” (with a correlation coefficient of 0.971 between and ). The effectiveness of the “shape-flow-effect” multi-scale flow-heat synergy framework is rooted in its core mechanism: the coupling effect between secondary flow induced by macro-helical ribs and micro-field synergy. Its validity has been quantitatively verified. Compared to optimization methods based on the Nusselt number () and pressure drop (), the average error rates of the optimization methods based on and are 0.37% and 0.41%, respectively. This confirms that , , and the heat transfer-flow resistance synergy number can effectively characterize heat transfer, flow resistance, and overall performance. This study, based on the “multi-scale flow-heat synergy” framework, systematically analyzes the synergy between heat transfer and flow resistance, providing new theoretical perspectives for enhancing heat transfer, supported by both qualitative and quantitative validation.
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