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Simulation and Optimization of Splayed heat Sink using COMSOL
Multiphysics® Software

Presenters
Takbeer Zahid (FA18-EPE-012)

Umar Rahman (FA18-EPE-015)

Muhammad Rehan (FA18-EPE-166)

Supervisor Engr. Zulfiqar Khattak

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Project Outline
 Introduction
 Types of heat sinks (Splayed and vertical heat sinks)
 Splayed heat sink
 Uses of heat sinks
 Literature Review
 Objectives
 Engineering Problem
 Work Flow
 Methodology
 CAD designs.
 The proposed solution
 Computational fluid dynamics (CFD) tool (COMSOL-Multiphysics)
 Meshing
 Mathematical expressions

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Contd.
 Results and discussion
 Unoptimized results
 Optimized results
 Societal Impact
 Environmental Impact
 Conclusion
 References

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Introduction

• The heat sink is typically a metallic heat exchanger

which can be attached to a device releasing energy in
the form of heat

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Types of heat sink [2]

Active Heat sink Passive Heat sink

 Those that rely on an incorporated

 Those that don't rely on forced air
fan flow (fans)

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 Modern Heat sinks

Splayed
SplayedpinHeat
heatsink
sink Vertical
StraightPinHeat
heat sink
sink

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 Splayed Heat Sink [4]

 Splayed heat sinks are relatively new derivatives of the standard pin fin heat
sink
 Unlike standard heat sink it contain an array of vertically oriented pins that
gradually bend outwards
 Curving the pins in this way increases the spacing between them
 Surface area of heat sink remains same.

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 Uses
 It is used in Solar MPPT.

 It is used for IC Cooling in an

electronics devices

 It is used in street light LED

 It is used in dc power supply

 It is used in Computer for IC cooling

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Literature Review
Previously, the work done on Heat Sink was based on
`

 Height of fins
 Distance between fins
 Size of heat sink
 Angle shift between fins
Optimization for enhancing efficiency was performed on
basis of the angle shift of fins (i.e )

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Objectives

 Thermal analysis simulation based on CFD for the

Heat Sinks under investigation (Vertical and Splayed
Heat Sinks)
 Study & Implementation of Optimization tool using
COMSOL Multiphysics® software
 Acquire Unoptimized and Optimized design results
 Comparison to determine the most efficient Heat
Sink.

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Engineering Problem

 Design and Thermal analysis of Splayed Heat

Sink using Optimization tools to attain the
optimum one in COMSOL Multiphysics®
Software

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Work Flow

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 Methodology
 Design CAD models and import it to COMSOL

 Thermal Analysis based on both Unoptimized and

Optimized techniques.

 Compare the results of both techniques to

determine the most efficient Heat Sink

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CAD Designs

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Proposed Solution
Optimizing commercial splayed heat sink on the basis of
parametric variations which are:
• Angle shift
• Fins diameter
• Material
• Size
Our main objective will be its optimization based on the
angle shift

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 Computational fluid dynamics (CFD) tool (COMSOL
Multiphysics)
 GUI Based Software
 Modeling and solving of mathematical and designing problem
 Geometry, mesh, visualization and results.
 Optimization Interface available

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 Meshing
 Meshing is one of the most important steps in performing an accurate
simulation using FEA (Finite Element Analysis)

 FEA is a convenient method to represent complex behaviors by accurately
capturing physical phenomena using partial differential equations

 We have used
 Coarse meshing

 Medium meshing

 Finer meshing

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Mathematical Expressions
 Heat Source
 Heat produced by the system at chip

is heat rate in Watt

is the volumetric heat in Watt/m^3
V is the heat source volume in m^3
 Heat Flux
 The rate of heat energy that passes through a surface of heat sink

is heat flux in Watt/m^2

A is the surface area of the fins in m^2

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Contd.
 Heat transfer convection coefficient
 The rate of heat transfer between fins and air per unit surface area per unit
temperature difference
 Its unit is

=
is change in temperature
is the heat co-efficient
q is the heat source

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Contd.
 Thermal Resistance

Its Unit is K/W

Where;
is thermal resistance
is temperature of base
is the area of fin
Q is heat rate in Watt

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Contd.

It has no unit because it is the ratio

ρ is the density of the fluid (kg/m3)
 is the flow speed (m/s)
L is a characteristic linear dimension (m)
μ is the dynamic viscosity of the fluid (kg/(m·s))

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Contd.

 Pressure Drop

 Its unit is pascal

 L is the length of the tunnel
 Re is the Reynold’s number
 Dh is the hydraulic diameter of tunnel
 F is the friction factor of heat sink

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Unoptimized results and discussion
 Unoptimized results
On this technique, the three investigated heat sinks has been studied
stationary with applying the same boundary conditions.

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Surface temperature(˚C)

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Velocity slices (m/s)

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Pressure variation inside Tunnel (Pa)

Pressure

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 Pressure Drop (Pa)

63 62.614

62
Pressure drop
60.979
Pressure Drop (Pa)

61

60 Angle(deg) Value (Pa)

59 58.82

58 58.82
75°

57
80° 60.979
56
74 76 78 80 82 84 86 88 90 92
Angle of fins 90° 62.614

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Friction factor
0.0061 0.0060479645275

0.006
Friction factor
0.0058434852455
0.0059
7
friction factor

0.0058 Angle Value

0.0057
0.0056174264636
75 0.005617426
0.0056

0.0055
80 0.005843485

0.0054
74 76 78 80 82 84 86 88 90 92

angle of fins 90 0.006047965

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 Air temperature at heat sink and tunnel outlet (K)

Maximum air temprature

Maximum air temperature
Air temprature at Air tempratur at
heat sink (k) tunnel outlet(K)

296.6

296.4
Air temprature Air tempratur at
296.2 Angle at
heat sink (k) tunnel outlet(K)
296

295.8

295.6

295.4 75 296.28 295.55

295.2
80 296.34 295.34
295

294.8 90 295.96 295.5

74 76 78 80 82 84 86 88 90 92

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 Air velocity at inlet and outlet

Air velocity Air velocity

inlet Velocity(m/s) outlet velcity(m/s)

10.6
10.375
10.4 10.293
10.258 outlet inlet velocity
10.169 Angle
10.2 velcity(m/s) (m/s)
10.005
10
veloccity (m/s)

9.8
9.6
75 9.3065 10.258
9.4 9.3065
9.2
9
80 10.005 10.293
8.8
8.6
74 76 78 80 82 84 86 88 90 92

angle of fins 90 10.169 10.375

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 Heat transfer Convection Coefficient
46.32108485594
46.35 22
Maximum Heat transfer convection

46.3
Heat transfer convection
46.25
coefficient (W/m^2.s)

coefficient
46.2
46.12596333117
46.15 38
Angle Value (W/m^2.s)
46.1
46.04260648375
6
46.05
75 46.04260648
46

45.95
80 46.12596333
45.9
74 76 78 80 82 84 86 88 90 92
angle of fins 90 46.32108486

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 Air convection Heat flux
1.06E+06
Air convection heat flux
Air convection heat flux (W/m^2)

1.05E+06
1.05E+06 Angle Value (W/m^2)

1.04E+06
75 1.04E+06
1.04E+06
1.04E+06

80 1.04E+06

1.03E+06
74 76 78 80 82 84 86 88 90 92 90 1.05E+06

Angle of fins

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Heat sink base temperature
296.5

296.38
Maximum heat sink temprature (k)

296.4

296.3 296.28 Heat sink base temperature

296.2

296.1
Angle Value (K)

296 295.96
75 296.28
295.9

295.8
80 296.38

295.7
74 76 78 80 82 84 86 88 90 92
90 295.96
Angle of fins

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Comparison of unoptimized results

 Taking 90 as a benchmark

Angle PD ff h0

90° 62.614 0.00604 46.321

80° -2.60% -3.30% -0.40%

75° -6% -7.10% -0.60%

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Optimization

Optimization is the process of changing the single parameter in order to

check the impact on its characteristics by keeping all the other parameters
constant.
 Techniques
 Size
 Height
 Fins angle shift
 Surface area of fins

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 Optimized method
 On this technique, the three investigated heat sinks has been studied by using the
optimization method to determine the most efficient model.
 The main goals from the optimization method are to: -
1- Investigate the performance of the three heat sinks from the fluid dynamics point of
view after changing the inlet velocity from 15 to 25 m/s.
2- Investigate the performance from the heat transfer point of view after changing the
natural heat transfer convection coefficient from 10 to 25 (W/(m^2.K)).

Optimization Objective
Point of view Control variable
method function
Inlet velocity
Fluid mechanics Air pressure drop
(15 to 25) m/s
Nelder-Mead
h0 from (10 to 25) Thermal
Heat transfer
(W/(m^2.K)) resistance

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 Pressure drop vs velocity
Pressure drop [Pa] 90°

1200
Vertical fins
1041.42
1000 1003.31 Velocity Pressure drop
930.038
[m/s] [Pa] 90°
855.34
800
pressure drop(Pa)

15 405.6494705
658.95
600 576.13
16.5 484.061
484.061 18 576.13
400 405.649470482577
19.5 658.95
200 22.5 855.34

23.5 930.038
0
15 17 19 21 23 25 27
24.5 1003.31
velocity (m/s)
25 1041.42

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Pressure drop vs velocity

Pressure drop [Pa] 80°

1600
Inclined fin 80
1400 1430
1377
1277 Pressure drop
1200 Velocity [m/s]
1177.31518553813 [Pa] 80°
pressure drop (Pa)

1000 15 522.3722637
883.727705027357
800 16.5 633.3785261
752.743809010792

600 633.378526078331 18 752.743809

522.372263713026
400 19.5 883.727705

22.5 1177.315186
200
23.5 1277
0
15 17 19 21 23 25 27
24.5 1377
velocity(m/s)
25 1430

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 Pressure drop vs velocity

Pressure drop[Pa] 75°

1600
1513.66
1459.265 Inclined fin 75
1400
1330.64
1225.93 Pressure drop[Pa]
1200 Velocity [m/s]
75°
1000
920.73 15 544.802285
Axis Title

800 784.501537520007 16.5 659.1878278

659.187827782195
600 18 784.5015375
544.80228501831

400 19.5 920.73

22.5 1225.93
200
23.5 1330.64
0
15 17 19 21 23 25 27
24.5 1459.265
Axis Title
25 1513.66

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 Optimization results
• Fluid mechanics perspective  Heat transfer perspective

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Comparison of optimized results

Angle Velocity(m/s) PD

90° 15m/s 405.64

80° 15m/s 28%(inc)

75° 15m/s 34%(inc)

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 Conclusion
 There was a tiny deviation in the performance of the three investigated heat
sinks when applying the unoptimized method. This is right because of the
small value of the input parameters that used such as air inlet velocity 5 m/s
and the natural convection coefficient of 10 W/(m^2.K).
 To solve this problem, the optimized method has been suggested to make a
great area of comparison by sweeping the inlet parameters from initial value to
final value instead of using only one value In the unoptimized method.
 From the optimized method specifically from the fluid dynamics point of view,
the splayed fins with angel 75 presents a great performance because it give the
greatest pressure drop and hence the greatest turbulence effect which will
enhance the heat transfer.
 From the heat transfer point of view, the thermal resistance for the three
investigated heat sinks was almost the same. This is right because of both base
area and fins area are almost the same for the three models.

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Societal Impact

 Increasing the life of Electronic Components

 Cost Effective
 Reliability

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Environmental Impact

 Environment Friendly

 Noise Free

 Easily Adjustable

 Energy Saving

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 References
 https://www.radianheatsinks.com/heatsink/
 K. Nishino et al., 1996. Turbulence statistics in the stagnation region of an axisymmetric impinging jet flow,
Int. J. Heat Fluid Flow, 17, 193-201
 https://www.google.com/search?
sxsrf=AOaemvLToDv4rbmCRhkJqtnzgWrZf5oUKQ:1633720629319&q=Heat+sink+types+and+design+pdf
&sa=X&ved=2ahUKEwiv_JbOw7vzAhXb8OAKHRg1AkkQ1QJ6BAgeEAE&biw=1455&bih=717&dpr=1.1
 https://uk.rs-online.com/web/generalDisplay.html?id=ideas-and-advice/heatsinks-guide
 https://www.ijert.org/research/cfd-analysis-of-splayed-pin-fin-heat-sink-for-electronic-cooling-
IJERTV1IS10473.pdf
 Khattak, Zulfiqar, and Hafiz Muhammad Ali. "Air cooled heat sink geometries subjected to forced flow: A
critical review." International Journal of Heat and Mass Transfer 130 (2019): 141-161.]
 A.Cengel, Yunus. "Numerical methods in heat conduction." In Heat and Mass Transfer, by Cengel. Mc
Grawhill, 2006. Engineering toolbox. thermal conductivity metals. n.d.
http://www.engineeringtoolbox.com/thermalconductivity-metals-d_858.html (accessed 11 20, 2016).

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