Abstract
Topology optimization of an air-cooled heat sink considering heat conduction plus side-surface convection is presented. The optimization formulation is explained along with multiple design examples. A postprocessing procedure is described to synthesize manifold or “water-tight” solid model computer-aided design (CAD) geometry from three-dimensional (3D) point-cloud data extracted from the optimization result. Using this process, a heat sink is optimized for confined jet impingement air cooling. A prototype structure is fabricated out of AlSi12 using additive layer manufacturing (ALM). The heat transfer and fluid flow performance of the optimized heat sink are experimentally evaluated, and the results are compared with benchmark plate and pin-fin heat sink geometries that are conventionally machined out of aluminum and copper. In two separate test cases, the experimental results indicate that the optimized ALM heat sink design has a higher coefficient of performance (COP) relative to the benchmark heat sink designs.
Issue Section:
Part Design Methods and Specification Challenges in AM
Topics:
Design,
Heat sinks,
Manufacturing,
Optimization,
Topology,
Convection,
Computer-aided design
References
1.
Tummala
, R.
, 2001
, Fundamentals of Microsystems Packaging
, McGraw-Hill
, New York
.2.
Incropera
, F. P.
, Dewitt
, D. P.
, Bergman
, T. L.
, and Lavine
, A. S.
, 2007
, Introduction to Heat Transfer
, Wiley
, New York
.3.
Kim
, S. J.
, and Lee
, S. W.
, 1996
, Air Cooling Technology for Electronic Equipment
, CRC, Inc.
, Boca Raton, FL
.4.
Incropera
, F. P.
, 1999
, Liquid Cooling of Electronics Devices by Single-Phase Convection
, Wiley
, New York
.5.
Mudawar
, I.
, 2011
, “Two-Phase Micro-Channel Heat Sinks: Theory, Applications and Limitations
,” ASME
Paper No. AJTEC2011-44005.6.
Sharar
, D. J.
, Morgan
, B.
, Jankowski
, N. R.
, and Bar-Cohen
, A.
, 2011
, “Two-Phase Minichannel Cold Plate for Army Vehicle Power Electronics
,” ASME
Paper No. IPACK2011-52079.7.
Dede
, E. M.
, 2012
, “Optimization and Design of a Multi-Pass Branching Microchannel Heat Sink for Electronics Cooling
,” ASME J. Electron. Packag.
, 134
(4
), p. 041001
.8.
Dede
, E. M.
, and Liu
, Y.
, 2013
, “Experimental and Numerical Investigation of a Multi-Pass Branching Microchannel Heat Sink
,” Appl. Therm. Eng.
, 55
(1–2
), pp. 51
–60
.9.
Koga
, A. A.
, Lopes
, E. C. C.
, Nova
, H. F. V.
, de Lima
, C. R.
, and Silva
, E. C. N.
, 2013
, “Development of Heat Sink Device by Using Topology Optimization
,” Int. J. Heat Mass Transfer
, 64
, pp. 759
–772
.10.
Dede
, E. M.
, Lee
, J.
, and Nomura
, T.
, 2014
, Multiphysics Simulation: Electromechanical System Applications and Optimization
, Springer
, London
.11.
Wits
, W. W.
, Weitkampa
, S. J.
, and van Esb
, J.
, 2013
, “Metal Additive Manufacturing of a High-Pressure Micro-Pump
,” Procedia CIRP
, 7
, pp. 252
–257
.12.
Wong
, M.
, Owen
, I.
, Sutcliffe
, C. J.
, and Puri
, A.
, 2009
, “Convective Heat Transfer and Pressure Losses Across Novel Heat Sinks Fabricated by Selective Laser Melting
,” Int. J. Heat Mass Transfer.
, 52
(1–2
), pp. 281
–288
.13.
Ventola
, L.
, Robottia
, F.
, Dialameha
, M.
, Calignanob
, F.
, Manfredib
, D.
, Chiavazzoa
, E.
, and Asinaria
, P.
, 2014
, “Rough Surfaces With Enhanced Heat Transfer for Electronics Cooling by Direct Metal Laser Sintering
,” Int. J. Heat Mass Transfer
, 75
, pp. 58
–74
.14.
Brackett
, D.
, Ashcroft
, I.
, and Hague
, R.
, 2011
, “Topology Optimization for Additive Manufacturing
,” 24th Solid Freeform Fabrication Symposium
.15.
Meisel
, N.
, Gaynor
, A.
, Williams
, C.
, and Guest
, J.
, 2013
, “Multiple-Material Topology Optimization of Compliant Mechanisms Created Via Polyjet 3D Printing
,” 24th Annual International Solid Freeform Fabrication Symposium—An Additive Manufacturing Conference
.16.
Bendsøe
, M. P.
, and Kikuchi
, N.
, 1988
, “Generating Optimal Topologies in Structural Design Using a Homogenization Method
,” Comput. Methods Appl. Mech. Eng.
, 71
(2
), pp. 197
–224
.17.
Bendsøe
, M. P.
, and Sigmund
, O.
, 2004
, Topology Optimization—Theory, Methods, and Applications
, 2nd ed., Springer
, Berlin
.18.
Torquato
, S.
, Hyun
, S.
, and Donev
, A.
, 2002
, “Multifunctional Composites: Optimizing Microstructures for Simultaneous Transport of Heat and Electricity
,” Phys. Rev. Lett.
, 89
(26
), p. 266601
.19.
Bruns
, T. E.
, 2007
, “Topology Optimization of Convection-Dominated, Steady-State Heat Transfer Problems
,” Int. J. Heat Mass Transfer
, 50
(15–16
), pp. 2859
–2873
.20.
Iga
, A.
, Nishiwaki
, S.
, Izui
, K.
, and Yoshimura
, M.
, 2009
, “Topology Optimization for Thermal Conductors Considering Design-Dependent Effects, Including Heat Conduction and Convection
,” Int. J. Heat Mass Transfer
, 52
(11–12
), pp. 2721
–2732
.21.
Yoon
, G. H.
, 2010
, “Topological Design of Heat Dissipating Structure With Forced Convective Heat Transfer
,” J. Mech. Sci. Technol.
, 24
(6
), pp. 1225
–1233
.22.
Alexandersen
, J.
, Aage
, N.
, Andreasen
, C. S.
, and Sigmund
, O.
, 2014
, “Topology Optimisation for Natural Convection Problems
,” Int. J. Numer. Methods Fluids
, 76
(10
), pp. 699
–721
.23.
Svanberg
, K.
, 1987
, “The Method of Moving Asymptotes—A New Method for Structural Optimization
,” Int. J. Numer. Methods Eng.
, 24
(2
), pp. 359
–373
.24.
COMSOL AB,
2008
, COMSOL Multiphysics ver. 3.5a.25.
Kawamoto
, A.
, Matsumori
, T.
, Yamasaki
, S.
, Nomura
, T.
, Kondoh
, T.
, and Nishiwaki
, S.
, 2011
, “Heaviside Projection Based Topology Optimization by a PDE-Filtered Scalar Function
,” Struct. Multidisicip. Optim.
, 44
(1
), pp. 19
–24
.26.
27.
28.
Schroeder
, V. P.
, and Garimella
, S. V.
, 1998
, “Heat Transfer From a Discrete Heat Source in Confined Air Jet Impingement
,” 11th IHTC
, Vol. 5
. August 23–28, Kyongju, Korea
.29.
El-Sheikh
, H. A.
, and Garimella
, S. V.
, 2000
, “Enhancement of Air Jet Impingement Heat Transfer Using Pin-Fin Heat Sinks
,” IEEE Trans. Compon. Packag. Technol.
, 23
(2
), pp. 300
–308
.30.
Issa
, J. A.
, and Ortega
, A.
, 2006
, “Experimental Measurements of the Flow and Heat Transfer of a Square Jet Impinging on an Array of Square Pin Fins
,” ASME J. Electron. Packag.
, 128
(1
), pp. 61
–70
.31.
Koguchi
, A.
, and Kikuchi
, N.
, 2006
, “A Surface Reconstruction Algorithm for Topology Optimization
,” Eng. Comput.
, 22
(1
), pp. 1
–10
.32.
33.
Dassault Systemes
, 2013
, Solidworks Premium ver. SP4.0.34.
Mercury Centre
, 2015
, “Additive Layer Manufacture
,” http://mercurycentre.org/facilities/additive-layer-manufacture 35.
Yu
, S.-H.
, Lee
, K.-S.
, and Yook
, S.-J.
, 2011
, “Optimum Design of a Radial Heat Sink Under Natural Convection
,” Int. J. Heat Mass Transfer
, 54
(11–12
), pp. 2499
–2505
.36.
Li
, H.-Y.
, and Chen
, K.-Y.
, 2007
, “Thermal Performance of Plate-Fin Heat Sinks Under Confined Impinging Jet Conditions
,” Int. J. Heat Mass Transfer
, 50
(9–10
), pp. 1963
–1970
.37.
Bejan
, A.
, Dincer
, I.
, Lorente
, S.
, Miguel
, A.
, and Reis
, H.
, 2004
, Porous and Complex Flow Structures in Modern Technologies
, Springer-Verlag
, New York
.38.
Joshi
, S. N.
, and Dede
, E. M.
, 2015
, “Effect of Sub-Cooling on Performance of a Multi-Jet Two Phase Cooler With Multi-Scale Porous Surfaces
,” Int. J. Therm. Sci.
, 87
, pp. 110
–120
.39.
Obot
, N. T.
, and Trabold
, T. A.
, 1987
, “Impingement Heat Transfer Within Arrays of Circular Jets: Part 1—Effect of Minimum, Intermediate, and Complete Crossflow for Small and Large Spacings
,” ASME J. Heat Transfer
, 109
(4
), pp. 872
–879
.Copyright © 2015 by ASME
You do not currently have access to this content.
