1

The University of Nottingham, Malaysia Campus

Faculty of Engineering

Department of Mechanical, Materials and Manufacturing Engineering


PROJECT TITLE: OPTIMIZATION OF COOLING PERFORMACE BASED ON EXTENDED RIB SURFACE OF A
DIFFERENT RIB PROFILE IN A MICROCHANNEL HEAT SINK.

NAME : KHAWAJA AQIB AZIZ
STUDENT ID : 009973
SESSION : 2013/2014
SUPERVISOR : DR. WONG KOK CHEONG




Individual Project Report submitted for the degree of Bachelor of Engineering / Master of
Engineering in Mechanical Engineering.
2

Summary
A Numerical Study is undertaken to optimize the Cooling performance of a micro-channel
heat sink, with application to the extended surface of a rib profile. The heat transfer
characteristics of the heat sink are investigated numerically using 3D conjugate heat transfer
modelling using ANSYS Fluent [12]. The model is validated with literature and is found in
good agreement with the experimental results of Lee et Al. [7]; also the computational
domain is based on the physical heat sink from this study.
Subsequently Ribs are added onto the validated heat sink and hence cases are generated to
optimize the cooling performance. Ribs are added inside the cooling channel to increase the
area available for transfer and to induce flow mixing. New cases are generalized in two
groups of Single Rib and Double Rib and results are presented. Number of Ribs and Length
of the Ribs are the parameters varied to check the best configuration of the Heat Sink.
The Double Rib (15mm) Heat Sink significantly improves in Heat Transfer performance for
all Reynolds Number tested (Re 500-2000). This proved to be the most successful
optimization case.





(Main Body word count: 6040 words)
3

Acknowledgements
I would like to thank my final year project supervisor Dr. Wong Kok Cheong for his support
and guidance throughout the project. The support I have received has played an integral role
in me finishing this investigation successfully.
4

Contents

Summary .............................................................................................................................................................................. 2
Acknowledgements ......................................................................................................................................................... 3
Contents ................................................................................................................................................................................ 4
Nomenclature ..................................................................................................................................................................... 6
List of Figures ..................................................................................................................................................................... 7
List of Tables ....................................................................................................................................................................... 8
1.0 Introduction ................................................................................................................................................................ 9
1.1 Background .......................................................................................................................................................... 10
1.2 Project Objectives .............................................................................................................................................. 11
1.3 Research Questions .......................................................................................................................................... 12
1.4 Outline of report ................................................................................................................................................ 13
2.0 Literature Review .................................................................................................................................................. 14
3.0 Computational Methodology ............................................................................................................................. 16
3.1 Numerical Methods .......................................................................................................................................... 16
3.2 Setup ....................................................................................................................................................................... 17
3.2.1 Physical Model ........................................................................................................................................... 17
3.2.2 Computational Domain and Meshing ............................................................................................... 18
3.2.3 Computational Domain for different Cases .................................................................................... 19
3.3 Meshing ................................................................................................................................................................. 22
3.4 Governing Equations........................................................................................................................................ 23
3.7 Dimensionless Parameters ............................................................................................................................ 25
3.7.1 Deriving Dimensionless Parameters ................................................................................................ 25
3.7.2 Temperatures to Extract from ANSYS Fluent ............................................................................... 26
3.5 Boundary Conditions ....................................................................................................................................... 27
3.6 Assumptions and Other Properties ........................................................................................................... 28

5

4.0 Results and Discussion ........................................................................................................................................ 29
4.1 Validation.............................................................................................................................................................. 29
4.2 Grid Independence ........................................................................................................................................... 31
4.3 Mesh Refinement ............................................................................................................................................... 32
4.4 Case Studies ......................................................................................................................................................... 33
4.4.1 Contours of Pressure, Velocity and Temperature for all Cases ............................................. 33
4.4.2 Comparing Heat Transfer Performance .......................................................................................... 39
4.4.3 Comparing Pressure Loss ...................................................................................................................... 41
4.4.4 Quantitative Comparison for all Cases ............................................................................................. 42
4.4.5 Overall Discussion .................................................................................................................................... 43
4.4.6 Further Recommendations ................................................................................................................... 44
5.0 Conclusions ............................................................................................................................................................... 45
References ........................................................................................................................................................................ 46
Appendix ........................................................................................................................................................................... 48



6

Nomenclature

Average Temperature of Wall

Width of micro-channel

Average Fluid Temperature

Height of micro-channel

Average Outlet Temperature

Length of Heat Sink

Average Inlet Temperature

Rib height

Density of Fluid (water)

Rib width

Volumetric Flow Rate of Fluid

Rib length

Specific Heat Capacity of Fluid

Height of Heat Sink

Heat gained by Coolant

Velocity in x-direction

Number of Channels

Velocity in y-direction

Area available for Heat Transfer

Velocity in z-direction

Average Heat Transfer Coefficient

Thermal Conductivity of Solid

Hydraulic Diameter

Thermal Conductivity of Fluid

Average Nusselt Number

Reynolds Number

Velocity

Dynamic Viscosity of Fluid

7

List of Figures
Figure 1.1: Fan cooled Micro-Channel Heat Sink, by Fir0002/Flagstaffotos [1] .................................... 9
Figure 1.2: Extended Ribs in a Micro Channel adapted from Gholami et Al. [3] ................................. 10
Figure 3.1 Schematic of the Physical Heat Sink................................................................................................. 17
Figure 3.2 Halved Single Unit of Micro-Channel ............................................................................................... 18
Figure 3.3: View of the domain geometry ........................................................................................................... 19
Figure 3.4: Modelled domain of Case 1 ( ) ..................................................................................... 20
Figure 3.5: Modelled domain of Case 3 ( )................................................................................... 20
Figure 3.6: Modelled domain of Case 5 ( ) ..................................................................................... 21
Figure 3.7: Modelled domain of Case 6 ( )................................................................................... 21
Figure 3.8: Front View of Mesh ................................................................................................................................ 22
Figure 3.9: Side View of the Mesh ........................................................................................................................... 22
Figure 3.10: Boundary Conditions for the Model Domain ............................................................................ 27
Figure 4.1: Comparison of results from Numerical study with experimental scatter ...................... 29
Figure 4.2: Different Mesh Generated for Grid Independance ................................................................... 31
Figure 4.3: Resulting Mesh after Refinement..................................................................................................... 32
Figure 4.4: Case 1, Contour of Pressure ............................................................................................................... 33
Figure 4.5: Case 1, Contour of Temperature ...................................................................................................... 34
Figure 4.6: Case 1, Contour of Velocity ................................................................................................................. 34
Figure 4.7: Case 2, Contour of Pressure ............................................................................................................... 35
Figure 4.8: Case 2, Contour of Temperature ...................................................................................................... 35
Figure 4.9: Case 2, Contour of Velocity ................................................................................................................. 35
Figure 4.10: Case 3, Contour of Pressure ............................................................................................................. 36
Figure 4.11: Case 3, Contour of Temperature .................................................................................................... 36
Figure 4.12: Case 3, Contour of Velocity .............................................................................................................. 36
Figure 4.13: Case 5, Contour of Pressure ............................................................................................................. 37
Figure 4.14: Case 5, Contour of Temperature .................................................................................................... 37
Figure 4.15: Case 5, Contour of Velocity .............................................................................................................. 37
Figure 4.16: Case 6, Contour of Pressure ............................................................................................................. 38
Figure 4.17: Case 6, Contour of Temperature .................................................................................................... 38
Figure 4.18: Case 6, Contour of Velocity .............................................................................................................. 38
Figure 4.19: Nusselt Number for Single Rib Cases........................................................................................... 39
Figure 4.20: Nusselt Number for Double Rib Cases ........................................................................................ 40
Figure 4.21: Pressure Loss for all Cases ............................................................................................................... 41

8

List of Tables
Table 3.1: Dimensions of the micro-channel ...................................................................................................... 17
Table 4.1: Comparing Nusselt Number and Experimental Values from Lee et. Al. [7] ..................... 30
Table 4.2: Nusselt Number corresponding to the Mesh Used ..................................................................... 31
Table 4.3: Quantitative comparison of Heat Transfer and Pressure Loss for Single Rib ................. 42
Table 4.4: Quantitative comparison of Heat Transfer and Pressure Loss for Double Rib ............... 42

9

1.0 Introduction
A Heat Sink is fitted to or is incorporated with systems to ensure that the operating
temperature does not exceed the maximum allowable limit. They are used with devices which
do not have the ability to cool themselves down; common examples include high power
semiconductors or Light Emitting Diodes (LEDs).
For effective operation, a Heat Sink is designed to maximize its area of contact with the
coolant (e.g. Surrounding Air or Water). Furthermore, Heat Sinks are either assembled onto
devices or are manufactured as an integral part of the device.


Figure 1: Fan cooled Micro-Channel Heat Sink, by Fir0002/Flagstaffotos [1]

Micro Channel Heat Sinks were initially suggested by Tuckerman & Pease [2]; they observed
improvements in the Heat Transfer by reducing the cooling channel to the micron scale.
These multiple cooling channels are machined into the back of the substrate of electronic
components, heat is transferred to the substrate by conduction and out from the substrate via
convection. Micro Channel Heat Sinks are compact, relatively simple and hence a very
feasible and worthwhile option to consider for Heat Removal applications.

10

1.1 Background
This report is based on optimization of cooling performance, by testing different
configurations of extended ribs in the micro-channel. Extended Ribs as can be seen from
Figure 1.2 are protrusions in the micro-channel.
These protrusions improve heat transfer. Firstly due to the increased surface area for transfer
between the coolant and the heat sink. Secondly by inducing further flow mixing and thereby
giving better heat transfer. Also due to the decreased flow area and turbulence for the coolant,
flow resistance is induced.


Figure 2: Extended Ribs in a Micro Channel adapted from Gholami et Al. [3]

Whereas the extended ribs better the heat transfer, the flow resistance present is an unwanted
consequence. The flow resistance deters the flow of coolant through the channel adversely
affecting the heat transfer. Prompting the use of fans and pumps, which are used to force the
coolant through the micro-channel.
Due to this conflicting situation the reduction of flow resistance is very important and has
been studied with great interest.

Extended Ribs in a Micro
Channel
11

1.2 Project Objectives
Aims:
To Optimize Heat Transfer by application to extended ribs in a micro-channel Heat
Sink.
Objectives:
To use Computational Methods to solve the given problem.
To Validate the Numerical Model with Experimental Literature.
To Generate Cases to optimize the Cooling Performance.
To understand the effect of Ribs on Heat Transfer and Fluid Flow.
To propose a feasible configurations of ribs in the micro-channel Heat Sink.



12

1.3 Research Questions
The work required in this project puts forth the following research questions:
1. Can Numerical Methods be employed to accurately predict and observe the Heat
Transfer and Coolant Flow through the Micro-Channel?
i. What are the best Numerical Methods available for this purpose?
ii. What are the limitations of Numerical Methods?
2. How to ensure that the Numerical Simulation is Correct?
i. What data is going to be used for Validation?
ii. What geometry is going to be employed?
iii. What simplifying assumptions can be applied to the system?
3. What sort of Extended Rib Profiles should be modelled?
i. What existing study of Ribs is available?
ii. What already has been deduced about Extended Rib Profiles?
iii. Are the any recommendations for Rib Profile designs?

13

1.4 Outline of report
The following text presents the sequential order of the report, and its encompassing sections.
2.0 Literature Review:
This section explains the past work done on micro channel heat sinks, discusses the
applicability of numerical techniques and their setup. Heat Transfer characteristics are
discussed as well as the best configurations to get maximised heat transfer.
3.0 Computational Methodology
This section presents the methodology put forth to solve the problem. Starting with
the model selection, to domain modelling, forth to the background governing
equations, domain meshing. The boundary conditions, properties and other
assumptions to solve the equations are discussed. Test cases are also discussed.
4.0 Results and Discussion
This section presents the results obtained by running the computation. Initially the
computation is validation with experimental results; then the best mesh is selected and
then refined.
The results of the test cases are presented and discussed; these discussions include
comments on the contours of pressure, velocity and temperature, graphs of Nusselt
Number against Reynolds Number and the comparison of pressure drop.
5.0 Conclusion
The main conclusions are drawn and put forth.



14

2.0 Literature Review
Heat Transfer in Micro-channel Heat Sinks has been studied with great interest by a lot of
researchers. Some of the important and relevant works are summarised below.
The pioneers were Tuckerman and Pease [2], who initially put forth the idea of using micro
channels to remove heat, they decreased the cooling channel size to the micron scale that
subsequently increased the heat transfer rates. The heat sink was tested up to 790 W/cm
2
, and
chip temperatures were maintained below 110C.
Qu and Mudawar [4] investigated the pressure drop and the heat transfer for a micro channel
both numerically and experimentally. There results demonstrated a good correlation between
the numerical and the experimental analysis. The study concluded that the Navier-Stokes and
energy equations can reasonably accurately predict the fluid flow and heat transfer for a
Micro-channel Heat Sink.
Gunnasegaran et al. [5] numerically using the finite volume method investigated effect of
geometric parameters on the water flow and heat transfer characteristics. The journal
concluded that the Micro-channel Heat Sinks with the lowest Hydraulic Diameter had the
better heat transfer and was also better for Pressure Drop.
Mansoor et Al. [6] carried out a 3D conjugate numerical investigation for a rectangular
Micro-channel Heat Sink to predict the heat transfer. The model had simultaneously
developed single-phase flow regime and was compared with experimental and numerical
results from previous studies. Overall this study was in good agreement with previous results.
The study concluded that for increasing heat flux, the heat transfer coefficient increases.
Lee et Al. [7] carried out both experimental and numerical analysis for the micro-channel
heat sink for a range of dimensions. The experimental investigation validated the classical
correlations and was found to be in agreement with them. The analysis concluded that a
conventional numerical method can predict the heat transfer in micro channels but the
entrance and boundary conditions need to be carefully considered and set according to real
conditions.
Kamali and Binesh [8] carried out investigation of ribbed duct flow. A computer code was
developed to simulate turbulent flow past ribs of four different shape inside the duct. It was
seen that heat transfer coefficient and pressure loss is greatly affected by rib shapes. The
15

trapezoidal shaped ribs provide the highest enhancement of both heat transfer and pressure
drop.
Liu et al. [9] studied forced convective heat transfer in Micro-channel Heat Sink using both
Computational Fluid Dynamics (CFD) and Lattice Boltzmann (LB) approaches. It is
concluded that both these methods are valid for predicting fluid flow and heat transfer in
micro channels. There were a few important observations from this study. Firstly it is found
that heat transfer efficiency is increased with an increase in Reynolds number. Secondly, the
shield shaped groove micro channel has the highest heat exchange performance.
Lee and Garimella [10] performed numerical simulations to investigate convective heat
transfer in micro channels of different aspect ratios. The study proposes optimization
correlations that show very good agreement with the experimental data.
Cui and Fu [11] relate to the bionic micro grooved surfaces on fish. It investigated whether a
bionic microgroove can reduce pressure loss in the channels of a MCHS. For that purpose
different types of bionic surfaces are tested. LB approach is used for the numerical analysis.
It is concluded that the ridge shaped grooved surface has the greatest drag reduction. It is also
seen that larger width to height ratio of ridge shaped groove are more suitable for larger
Reynolds number.
Lei et Al. [13] used criss cross configuration for cooling channels and found increase in heat
transfer above Re = 300. Moradi and Floryan [14] proposed and used grooves parallel to the
flow direction to improve heat transfer. Xie et Al. [15] used internal protruded dimples and
found the case where the difference between dimples is 16mm to have the best heat transfer
for least pressure loss.
Xia et Al. [16] fan-shaped re-entrant cavities and internal ribs and found the best performance
for the case where cavity and ribs both were used. Ahmed et Al. [17] used both vortex
generators and nano-fluids; they concluded that although heat transfer is improved greatly but
presents a pressure deficit.
As can be seen there is a lot of research material available on the MCHS. However there is a
research gap, not much study is done on the extended rib profile. Hence we will study the
effects on extended ribs.

16

3.0 Computational Methodology
3.1 Numerical Methods
Numerical Methods are employed to perform this study. Using the numerical study there is a
greater flexibility to vary different parameters; more results are achieved in the same time
frame as compared to an experimental study. Also contours of Velocity, Temperature and
pressure can be easily obtained, that make the visualisation and understanding of the physical
phenomenon much simpler.
Numerical Methods usually employ Iterative techniques and computational tools to obtain
solutions where analytical solutions are not possible. For this study ANSYS Fluent [12] will
be used to obtain a 3D conjugate analysis accounting for both conduction inside the copper
substrate and for convection in the coolant flowing through the micro channel.
The computation setup is designed similar to the experimental work of Lee et Al. [7].

17

3.2 Setup
3.2.1 Physical Model
The physical model and its dimensions are shown in the schematic in Figure 3.1. The coolant
inlet and outlet configuration is also illustrated.

Figure 3 Schematic of the Physical Heat Sink
The heat sink substrate walls are set to 0.15mm. This value is arbitrary as the copper heat
sink is assumed to have perfect heat conduction. The top wall and the side walls are specified
as adiabatic walls.
Table 3.1: Dimensions of the micro-channel
Dimensions of the micro-channel

18

3.2.2 Computational Domain and Meshing
The computational domain is modelled using ANSYS Design Modeller [18]. Figure 3.2
shows the half micro-channel, on which the computational domain is based upon.


Figure 4 Halved Single Unit of Micro-Channel

The domain used for this simulation is half of a single Micro Channel; the simplification is
considered because of the apparent symmetry in the Heat Sink. Same behaviour will be
experienced from both inside walls of the micro-channel; hence having a symmetry boundary
condition will give us the same result, while halving the number of computational nodes and
the computational grid. This reduction of the Computational Grid and Number of Nodes will
reduce the computational power required without having to compromise on the accuracy of
our results.

19

3.2.3 Computational Domain for different Cases
As this investigation is based on the Extended Rib Surface, the cases developed are just
Ribs added onto the Bare Channel Heat Sink domain.
Figure 3.3 shows a bare channel computational domain; this will serve as the base model.
Ribs are added to the middle of this domain to generate cases.

Figure 5: View of the domain geometry

The cases developed either have Single Rib or Double Ribs. The Rib Length is going to be
varied (kept either 2mm or 5mm or 15mm) to see what effects Rib Length has on Heat
Transfer values and characteristics.
Apart from the bare channel, a total 6 cases are generated:
Case 1. Single Rib 2mm
Case 2. Single Rib 5mm
Case 3. Single Rib 15mm
Case 4. Double Rib 2mm
Case 5. Double Rib 5mm
Case 6. Double Rib 15mm

20

As the name suggests the Single Rib case supports a Single Rib right down the middle of
the Heat Sink. The Rib Height is

and the Rib width is

. The Ribs for all the cases start from after a length of 10.4mm from the
inlet. The variable parameter for these cases will be the Rib Length

.
Figure 3.4 below shows the modelled domain of case 1. Successively the following figures
show the modelled domain for different cases.

Figure 6: Modelled domain of Case 1 (

)


Figure 7: Modelled domain of Case 3 (

)

21

The subsequent figures below show the Cases for Double Ribs. For these cases the Rib width
is

and the Rib height is

.


Figure 8: Modelled domain of Case 5 (

)

Figure 9: Modelled domain of Case 6 (

)

22

3.3 Meshing
The Computational Domain is meshed using a regular rectangular grid; which is composed of

elements. The Mesh is further refined and developed; the Refinement and
Development is discussed further in sections 4.2 and 4.3.

Figure 10: Front View of Mesh


Figure 11: Side View of the Mesh


23

3.4 Governing Equations
To model the solid and fluid behaviour differential equations are used. These equations
known as the governing equations are solved using computational methods. These
governing equations govern the phenomenon occurring both in solids and liquids.
Firstly for the fluid flow there are governing equations for the continuity (conservation of
mass) and momentum (conservation of momentum).
Secondly for the heat transfer modelling there are governing equations for Heat Transfer in
the Fluid and Heat Transfer in the Solid.

Equation 1: the Continuity Equation

Equation 2: the Momentum Equations
(

)
(

)
(

)




24

Equation 3: the Energy Equation (Fluid)

]
[(

]
(

Equation 4: the Energy Equation (Solid)

]


ANSYS Fluent [12] is used to iterate these equations to solve for the fluid and heat transfer
behaviour. These governing equations are discretised using the first order upward scheme.
The pressure-velocity coupling is done using the SIMPLE scheme. The convergence criteria
was kept

for the residuals for the solution to converge.

Dimensionless parameters are used to evaluate the Heat Transfer Characteristics.
These dimensionless numbers and their derivation are discussed in the next section.

25

3.7 Dimensionless Parameters
To evaluate the Heat Transfer and Fluid Flow, Average Nusselt Number and Reynolds
number are derived respectively.
Nusselt number is the ratio of convective heat transfer to conductive heat transfer; a higher
Nusselt number implies greater convective heat transfer.
3.7.1 Deriving Dimensionless Parameters
The Heat Transferred to the coolant and is given by the following equation.
Equation 5: Heat Gain by Coolant

,
o Where the

term indicate the average rise in temperature of the

coolant, from the inlet to the outlet.
Once the Heat Transferred to the coolant is obtained, the Average Heat Transfer Coefficient
can be derived using its formula, the following equation:
Equation 6: Average Heat Transfer Coefficient

In the above formula the N represents the number of channels, and in this case its value is 1.
A is the area available for transfer and is the Surface Area in contact with the Fluid. The
Average Temperature of the Wall

is obtained using the software and the Average

Temperature of the Fluid

is obtained using the following equation.

Equation 7: Average Fluid Temperature

After the Average Heat Transfer Coefficient is obtained, the Average Nusselt Number is
calculated using the following equation.
Equation 8: Average Nusselt Number

o Where

is the Hydraulic Diameter and is the thermal conductivity.

26

The Nusselt Number obtained is dependent on the Reynolds number of the flow which is
calculated using the following equation.
Equation 9: Obtaining Reynolds Number

o Where the values of velocity v are varied in the ANSYS Fluent [12] software
to obtain the required Reynolds number.

3.7.2 Temperatures to Extract from ANSYS Fluent
As seen previously from the mathematical formulation there are 4 values of temperature
required. Table 2 below outlines where these values are extracted from.
Table 1: Temperature to Extract
Temperature Description

This is the average Inlet Temperature; this can be obtained from the
software from Reports. For our Study this is set and will always have a
value of 300k as it is specified in the software.

This is the average Outlet Temperature; this is to be extracted from
FLUENT [12] and should yield different values of greater than 300k
every test case.

This is the average Wall Temperature; this is to be similarly extracted
from FLUENT [12]. As Copper (Heat Sink Material set) has high
thermal Conductivity this can be assumed to be accurate

This is the average Fluid Temperature; although this can be also
extracted but for simplicity we use the inlet and outlet temperature and
equation 7 to calculate its value,


27

3.5 Boundary Conditions
These boundary conditions set for this investigation are as follows:

Figure 12: Boundary Conditions for the Model Domain

The Inlet Boundary condition is velocity-inlet.
o This is set as the velocity inlet because as depending on our case (Reynolds
Number of Flow) the entrance velocity of the coolant fluid would vary.
Outlet Boundary Condition: The Outlet Boundary condition is pressure based outlet.
o This specifies the point from where the fluid would exit and hence develops
the flow.
Bottom Wall Heat Flux: Bottom of the Heat Sink is set as Heat Flux.
o This is where the Heat is transferred to the Heat Sink.
Symmetry: The side walls are set as Symmetry.
o The side walls are set as Symmetry
Adiabatic Walls: The Remaining walls are set as Adiabatic Walls.
o This is in line with the simplifying assumption put on the experiment that
negligible heat loss to the environment.

28

3.6 Assumptions and Other Properties
The properties of the solid and fluid materials being used are very important. As properties of
the materials lie within a range at different operating conditions, it is important and
imperative that material properties are specified justified for their assumptions.
Hence firstly the assumptions for this study are specified and then the material properties are
specified.

The assumptions for this study are:
1. The Fluid Flow is laminar, steady and incompressible.
2. The Heat Loss to the environment is negligible.
3. Fluid properties are constant.

The Fluid for this study is Water and its properties are set as:
1. Density = 996.69 kg/m3
2. Specific Heat = 4187 J/kg.K
3. Thermal Conductivity = 0.6 W/m.K
4. Viscosity = 0.000852 kg/m.s

The Solid for this study is Copper and its properties are set as:
1. Density = 8978 kg/m3
2. Specific Heat = 381 j/kg.K
3. Thermal Conductivity = 387.6 w/m.K
29

4.0 Results and Discussion
4.1 Validation
Validation is performed to determine whether the computational simulation gives results
agreeing with the physical reality. To validate this simulation the results obtained are
compared with the experiment performed by Lee et Al. [7].
Figure 4.1 shows the comparison of our results with the results from experimental
investigation. These results are equated using the mathematical manipulation discussed in
section 3.7.1.


Figure 13: Comparison of results from Numerical study with experimental scatter

From figure 4.1 it is observed that Computational simulation accurately predicts the heat
transfer characteristics; similar to the experimental trend the Average Nusselt Number
increases as the Reynolds Number increases.
4
6
8
10
12
14
16
18
20
0 500 1000 1500 2000 2500

A
V
E
R
A
G
E

N
U
S
S
E
L
T

N
U
M
B
E
R

REYNOLDS NUMBER
Computational Data Experimental Data, Lee et. Al.
30

To complement the comparison using the graph, values at specific Reynolds numbers are also
compared. It can is seen from table 4.1 that the deviation in the experimental and
computational results does not increase more than 10% (which is the acceptable norm).


Table 4.1: Comparing Nusselt Number and Experimental Values from Lee et. Al. [7]
Re Nu (this study) Nu (Lee et. Al.) Difference
900 9.04 8.6 5.1%
1000 9.55 9 6.1%
1100 10.04 9.7 3.5%
1200 10.52 10 5.2%
1500 11.86 11 7.8%
2000 13.86 14.3 -3.0%


From both figure 4.1 and table 4.1, it is concluded that the results from the computational
simulation are close to the experimental scatter, and therefore it is concluded that the
computational simulation accurately predicts the physical reality.

31

4.2 Grid Independence
As the size of the mesh increases, the computational nodes also increase and consequently the
accuracy of the numerical study improves. This is observed because as the single mesh
element gets smaller it accounts for the smallest change, and overall better results will be
obtained.
Nonetheless there is a point when after the mesh size is further increased, the results do not
change; the results become mesh independent (or grid independent). At this point a relatively
coarser mesh has a similar value to a finer mesh; hence the increase in computation size and
cost is unnecessary. To find that mesh size a Grid Independence Test is performed.
Figure 4.2 indicates the Meshes generated for the same computational domain and Table 3
has the results obtained for the Nusselt Number at (Re=1000) using the various mesh sizes.

Figure 14: Different Mesh Generated for Grid Independance
Table 4.2: Nusselt Number corresponding to the Mesh Used
Mesh Type Mesh Size (elements) Nusselt Number
Coarse
1.9 x 10
4

9.50
Medium
1.6 x 10
5

9.71
Fine
3.6 x 10
5

9.74

It is observed that there is a very small difference in the value of Nusselt Number between the
Medium Mesh and the Fine Mesh; hence Medium Mesh would be selected.

32

4.3 Mesh Refinement
The mesh selected in section 4.2 is further modified at critical areas so phenomenon at those
critical areas in accounted for.
There are two critical areas identified in the domain where the mesh is then refined:
1. The Heat Flux at the bottom is a sensitive area, Energy rises from this point and
conduction starts. Any loss of data or oversimplification can make the results
inaccurate. Hence the Mesh Size here has to be increased.
2. The Solid-Fluid interface, where the coolant fluid is in contact with the solid heat
sink. Here the mesh on both the solid size and the liquid size has to be same size and
small enough so we dont have over simplification and subsequent loss of data.

Figure 15: Resulting Mesh after Refinement

Figure 4.3 shows the Mesh obtained after the refinement of critical areas. Medium Mesh from Figure
4.2 and the Refined Mesh from Figure 4.3 can be compared to see the refinement differences; at the
solid liquid interface and the bottom face.
33

4.4 Case Studies
Cases are generated with two variable parameters. These parameters are changed across the
six cases developed. The two variable parameters are:
1. Number of Ribs
2. Rib Length
The Resulting cases developed are:
Case 1. Single Rib 2mm
Case 2. Single Rib 5mm
Case 3. Single Rib 15mm
Case 4. Double Rib 2mm
Case 5. Double Rib 5mm
Case 6. Double Rib 15mm

4.4.1 Contours of Pressure, Velocity and Temperature for all Cases
For the case of Single Rib (2mm), it is seen from figure 4.4 that the extended rib induced
flow mixing and hence therefore there is an area of high pressure developed right after the rib
(the red region). The rib forms a bottleneck for the flow. The flow rapidly recovers to its
initial conditions further downstream.


Figure 16: Case 1, Contour of Pressure
34


Figure 17: Case 1, Contour of Temperature

Figure 18: Case 1, Contour of Velocity
From the contours of velocity it is observe that the velocity under the rib accelerated. Once
the stream was obstructed the expectation was for the fluid to equally disperse. Rather, it is
interesting to see that even though the rib is placed in the middle of the channel cross section,
after obstruction the coolant fluid accelerated under the rib. This happens because the fluid
finds it easier to move below rather than above the rib, there is lesser flow resistance under
side of the rib.
It is observed from the temperature contour in figure 4.5 that the temperature is higher in the
above the rib region. As earlier discussed the local flow for that region has reduced, leading
to reduced heat transfer and a rise in local temperature.

35


Figure 19: Case 2, Contour of Pressure

Figure 20: Case 2, Contour of Temperature

Figure 21: Case 2, Contour of Velocity
Similar phenomenon for pressure and velocity can be seen in figure 4.7 and figure 4.9 for
pressure and temperature respectively. There is a pressure rise in the rib region with the
velocity being accelerated below the rib. However because the Rib Length was more - 5mm
for this case, the turbulence caused by the disruption enables greater flow mixing and hence
more heat transfer which can be seen from figure 4.8. From figure 4.8 it is observed the
coolant temperature is cooler as compared to figure 4.5, hence more heat is transferred.
36


Figure 22: Case 3, Contour of Pressure

Figure 23: Case 3, Contour of Temperature

Figure 24: Case 3, Contour of Velocity
The 15mm Single Rib has a greater area available for convection. Also it has greater
obstruction for pressure loss. Figure 4.10 shows the pressure build-up in the channel and like
seen before its in the region under the rib. From figure 4.12 it can be seen there is a velocity
increase but not as quickly accelerated. The pressure loss in this channel is far too great to
benefit in heat transfer, and making it not feasible in application. Figure 4.11 shows heat
transfer taking place but slow adjacent to the rib.
37


Figure 25: Case 5, Contour of Pressure

Figure 26: Case 5, Contour of Temperature

Figure 27: Case 5, Contour of Velocity

The pressure contour for the 5mm Double Rib case can be seen from figure 4.13, unlike the
single Rib case the pressure is equally distributed past the ribs, and the velocity development
as seen from the velocity contour in figure 4.15 is evenly developed throughout the channel,
this results in even heat transfer throughout the channel. Figure 4.14, the temperature contour
for the coolant shows how the temperature distribution is even and hence, better heat transfer.
The 5mm is similar to the 2mm case; just the pressure developed is not much higher.


38


Figure 28: Case 6, Contour of Pressure

Figure 29: Case 6, Contour of Temperature

Figure 30: Case 6, Contour of Velocity

The 15mm Double Rib should in theory be similar to 15mm Single Rib case and because of
the increased flow blockage the heat transfer should be lesser than smaller rib counter parts. It
is seen from figure 4.17, the 15mm Double Rib has the best temperature distribution amongst
all the cases. Slow pressure development and velocity development can be seen from figure
4.16 and figure 4.18 respectively.
39

4.4.2 Comparing Heat Transfer Performance
Heat Transfer Performance is described using Nusselt Number. These Nusselt Numbers are
derived using the equations from section 3.7.2. The Nusselt Number is plot corresponding to
the Reynolds Number of the Flow.

Figure 31: Nusselt Number for Single Rib Cases

Figure 4.19 compares the heat transfer performance of the newly generated cases with the
bare channel case. In figure 4.19 the lines for bare channel, 2mm and 5mm approximately
overlap each other and have negligible difference except for high Reynolds Number.
Therefore we can conclude that the newly generated cases do not improve the Heat Transfer
performance except for high Reynolds Number. For the Case 4 (Single Rib 15mm) the line is
below the bare channel line and hence it actually has a decrease in the Heat Transfer
Performance.
It can be seen that none of these cases give a noticeable Heat Transfer increase, hence it will
not be feasible to use any of them for application. Also we note that Case 3, which is the
Single Rib 15mm has a reduced heat transfer performance. Looking also at figure 4.21 we
can see that the Single Rib 15mm has the worst pressure loss; explaining even why the Heat
Transfer performance is worse off.
4.00
6.00
8.00
10.00
12.00
14.00
16.00
0 500 1000 1500 2000 2500
A
V
E
R
A
G
E

N
U
S
S
E
L
T

N
U
M
B
E
R

REYNOLDS NUMBER
Bare Channel 2mm 5mm 15mm
40



Figure 32: Nusselt Number for Double Rib Cases

Figure 4.20 has graphs for Case 4, 5 and 6. Again from the figure it is seen that the Case 4
(2mm) and Case 5 (5mm) lines are overlapping hence negligible Heat Transfer performance
variation. For Case 6 (15mm) the line is over the bare channel line hence there is an
increase in the heat transfer performance. This improvement in the Heat Transfer can be
attributed to the increased surface area for Heat Transfer. It can also be attributed to the better
flow pattern for the coolant flow as seen from the pressure and velocity contours.

4.00
6.00
8.00
10.00
12.00
14.00
16.00
0 500 1000 1500 2000 2500
A
V
E
R
A
G
E

N
U
S
S
E
L
T

N
U
M
B
E
R

REYNOLDS NUMBER
Bare Channel 2mm 5mm 15mm
41

4.4.3 Comparing Pressure Loss

Figure 33: Pressure Loss for all Cases
Figure 4.21 is a graph of Pressure Loss for all the cases. The Pressure Loss in all the Rib
configurations is compared. It is seen from the Graph that the Pressure Loss for the Single Rib cases is
generally higher than their Double Rib counterparts.
As expected the worst pressure loss is for Case 3 (Double Rib 15mm). As pressure loss happens the
flow is greatly affected. The coolant is not as frequently being supplied, heat transfer reduces and
hence overall temperature increases.
The Best Heat Transfer case was Case 6 (Double Rib 15mm); the Pressure Loss was greater than the
other Double Rib cases. We can also conclude that for these channel dimensions up till Pressure Loss
of 80kPa the Heat Transfer performance continues to increase.

0.00
20.00
40.00
60.00
80.00
100.00
120.00
0 500 1000 1500 2000 2500
P
R
E
S
S
U
R
E

D
R
O
P

(
K
P
A
)

REYNOLDS NUMBER
Single Rib (2mm) Single Rib (5mm) Single Rib (15mm)
Double Rib (2mm) Double Rib (5mm) Double Rib (15mm)
42

4.4.4 Quantitative Comparison for all Cases

Table 4.3: Quantitative comparison of Heat Transfer and Pressure Loss for Single Rib
Nusselt Number Pressure Drop (kPa)
Re
Case 1
(2mm)
Case 2
(5mm)
Case 3
(15mm)
Bare
Channel
Case 1
(2mm)
Case 2
(5mm)
Case 3
(15mm)
500 6.70 6.77 5.42 6.72 11.43 15.34 22.11
600 7.35 7.43 5.96 7.35 13.38 18.75 27.21
700 7.96 8.04 6.45 7.95 18.94 22.25 32.47
800 8.54 8.62 6.91 8.51 21.96 25.83 37.86
900 9.08 9.17 7.33 9.04 25.05 29.50 43.37
1000 9.62 9.70 7.72 9.55 28.26 33.25 48.99
1100 10.14 10.20 8.09 10.04 31.47 37.08 54.78
1200 10.63 10.70 8.46 10.52 34.79 40.99 60.50
1500 12.04 12.10 9.45 11.86 45.20 53.20 78.66
2000 14.15 14.22 10.89 13.86 63.99 75.12 110.67


Table 4.4: Quantitative comparison of Heat Transfer and Pressure Loss for Double Rib

Re
Nusselt Number Pressure Drop (kPa)
Case 4
(2mm)
Case 5
(5mm)
Case 6
(15mm) Bare Channel
Case 4
(2mm)
Case 5
(5mm)
Case 6
(15mm)
500 6.68 6.71 7.62 6.72 11.76 12.92 15.58
600 7.31 7.34 8.37 7.35 14.52 15.68 18.92
700 7.90 7.94 9.07 7.95 17.13 18.51 22.33
800 8.46 8.50 9.72 8.51 19.79 21.39 25.82
900 8.99 9.04 10.33 9.04 22.50 24.33 29.38
1000 9.51 9.57 10.91 9.55 25.27 27.33 33.01
1100 10.01 10.07 11.47 10.04 28.09 30.39 36.71
1200 10.49 10.56 12.00 10.52 30.97 33.51 40.47
1500 11.86 11.95 13.50 11.86 39.93 43.21 52.15
2000 13.94 14.06 15.72 13.86 51.67 60.54 72.83

Tables 4.3 and 4.4 summarize the Heat Transfer and Pressure Loss Values at certain flow
rates (fixed Reynolds Number). The values corresponding the best case are highlighted in
green and the values corresponding the worst case are highlighted in Red.


43

4.4.5 Overall Discussion
By looking at the results thus far it is evident that better distribution of the flow yields better
heat transfer performance. Simply comparing the contours of the Single Rib cases and the
Double Rib Cases, it is observed that where the flow development was uniform Heat Transfer
was better (also referring to their Temperature Contours).
In the case of Single Ribs it was seen from both the Velocity and Pressure Contours that
when the flow was obstructed by a Rib the flow becomes concentrated under the rib and the
region over the rib has lesser flow. This one sided flow results in a relatively large boundary
layer being created, which can be referred to as a dead layer (when speaking about heat
transfer). This dead layer hinders the heat transfer taking place.
Hence to disrupt the build-up of a dead layer we need to equally disrupt the flow in all
direction, by having a flow guiding rib, like a V-shape facing the flow. This phenomenon of
equally distributed flow is occurring in the Double Rib Cases. From the contours of Double
Ribs the evident pattern is seen and distribution is even. This distribution leads to the dead
layers being broken.
As spoken about earlier the flow obstruction helps because it breaks the dead layer, and when
the dead layer is continued to be replaced by new cooler fluid the heat transfer is enhanced.
Flow also has a better tendency to recover from an obstruction if the obstruction is parallel to
the line of the flow.
Although having a greater surface area for heat transfer improves the heat transfer, but the
flow regime is very important. From all the plots it is observed that at higher Reynolds
Number there is more Heat Transfer. This is owing to the quick replacement of the coolant
fluid.
By increasing the convective area flow blockages are included. Flow mixing occurs and
boundary layers are broken up, but the pressure loss has a greater negative effect than the
positives combined.
From the Double Rib cases it is seen that by dispersing the blockage into smaller parts
reducing the flow resistance significantly. Both the Single Rib and the Double Rib had the
same effective area for flow blockage. Their pressure loss and Heat Transfer should have
been similar. The blockage was divided into two parts (i.e. two smaller Ribs), and both Heat
Transfer was enhanced and Pressure Loss was reduced.
44

4.4.6 Further Recommendations
Heat Sink configurations have been studied with great interest. Different Inlet & Outlet
configurations have been studied. Different Base shapes, channel shapes, have been studied.
Different studies have provided Cooling Performance enhancements. However if these
enhancements are feasible or not is another question?
The problems posed by conventional heat sinks can be reduced by using an innovative design
e.g. Sandia Cooler [19], which itself is a fan shaped heat sink. This Heat sink is rotating, and
as it rotates it dispenses hot air out from the sides while sucking in cool air from the top. This
design does not let the dead layer to accumulate. This is a big step in Heat Sinking
technology.

45

5.0 Conclusions
There are a number of observations from the 6 test cases performed. The best Heat Transfer
performance was seen in case 6 (Double Rib-15mm), the worst heat transfer was seen in case
3 (Single Rib-15mm) and all the other cases did not significantly alter the heat transfer
performance as compared to bare channel heat sink.
The observations made from the study and the conclusions developed are listed below:
1. Heat Transfer is accurately predicted using ANSYS Fluent [12].
2. Heat Transfer by increasing the area of convection is increased only if sufficient area
is increased.
3. By increasing the blockage pressure loss occurs, which reduces coolant flow and
hence reducing heat transfer.
4. Flow blockage forces flow to be concentrated in some regions therefore greater
pressure loss reducing heat transfer.
5. Ribs are desirable if they disperse the fluid into a pattern so fluid distribution is even,
not concentrated at some end.
6. Boundary layer build up at walls, acts as a dead layer which if not disturbed or
removed will not let efficient heat transfer take place.


46

References
1. Fir0002/Flagstaffotos, (2006). AMD Heat Sink and Fan. [image] Available at:
http://upload.wikimedia.org/wikipedia/commons/2/25/AMD_heatsink_and_fan.jpg
[Accessed 24 Apr. 2014].
2. Tuckerman, D. and Pease, R. (1981). High-performance heat sinking for VLSI.
Electron Device Letters, IEEE, 2(5), pp.126--129.
3. Gholami, H., Banaei, M. and Eskandari, A. (2013). Investigation of effect of
triangular rib in heat transfer of finned rectangular microchannel with extended
surfaces. Life Science Journal, 10(8s).
4. Qu, W. and Mudawar, I. (2002). Experimental and numerical study of pressure drop
and heat transfer in a single-phase micro-channel heat sink. International Journal of
Heat and Mass Transfer, 45(12), pp.2549--2565.
5. Gunnasegaran, P., Mohammed, H., Shuaib, N. and Saidur, R. (2010). The effect of
geometrical parameters on heat transfer characteristics of microchannels heat sink
with different shapes. International Communications in Heat and Mass Transfer,
37(8), pp.1078--1086.
6. Mansoor, M., Wong, K. and Siddique, M. (2012). Numerical investigation of fluid
flow and heat transfer under high heat flux using rectangular micro-channels.
International Communications in Heat and Mass Transfer, 39(2), pp.291--297.
7. Lee, P., Garimella, S. and Liu, D. (2005). Investigation of heat transfer in rectangular
microchannels. International Journal of Heat and Mass Transfer, 48(9), pp.1688--
1704.
8. Kamali, R. and Binesh, A. (2008). The importance of rib shape effects on the local
heat transfer and flow friction characteristics of square ducts with ribbed internal
surfaces. International Communications in Heat and Mass Transfer, 35(8), pp.1032--
1040.
9. Liu, Y., Cui, J., Jiang, Y. and Li, W. (2011). A numerical study on heat transfer
performance of microchannels with different surface microstructures. Applied
Thermal Engineering, 31(5), pp.921--931.
10. Lee, P. and Garimella, S. (2006). Thermally developing flow and heat transfer in
rectangular microchannels of different aspect ratios. international journal of heat and
mass transfer, 49(17), pp.3060--3067.
47

11. Cui, J. and Fu, Y. (2012). A numerical study on pressure drop in microchannel flow
with different bionic micro-grooved surfaces. Journal of Bionic Engineering, 9(1),
pp.99--109.
12. ANSYS FLUENT, Release 14.0, ANSYS, Inc. (2013)
13. Chai, L., Xia, G., Wang, L., Zhou, M. and Cui, Z. (2013). Heat transfer enhancement
in microchannel heat sinks with periodic expansion--constriction cross-sections.
International Journal of Heat and Mass Transfer, 62, pp.741--751.
14. Moradi, H. and Floryan, J. (2013). Maximization of heat transfer across micro-
channels. International Journal of Heat and Mass Transfer, 66, pp.517--530.
15. Xie, G., Liu, J., Ligrani, P. and Zhang, W. (2013). Numerical analysis of flow
structure and heat transfer characteristics in square channels with different internal-
protruded dimple geometrics. International Journal of Heat and Mass Transfer, 67,
pp.81--97.
16. Xia, G., Zhai, Y. and Cui, Z. (2013). Numerical investigation of thermal enhancement
in a micro heat sink with fan-shaped reentrant cavities and internal ribs. Applied
Thermal Engineering, 58(1), pp.52--60.
17. Ahmed, H., Mohammed, H. and Yusoff, M. (2012). An overview on heat transfer
augmentation using vortex generators and nanofluids: Approaches and applications.
Renewable and Sustainable Energy Reviews, 16(8), pp.5951--5993.
18. ANSYS DesignModeller, Release 14.0, ANSYS, Inc. (2013)
19. Ip.sandia.gov, (2011). Sandia National Laboratories: The Sandia Cooler. [online]
Available at: https://ip.sandia.gov/technology.do/techID=66 [Accessed 25 Apr. 2014].

48

Appendix


Appendix 1: Gantt chart used for Project Planning and Organization

Appendix 2: Validation using different turbulence models, k-3 and LES

49


Appendix 3: Calculating Velocity using Spreadsheet


Appendix 4: Calculating Heat Transferred using Spreadsheet


Appendix 5: Calculating Nusselt Number using Spreadsheet
50


Appendix 6: Flow of work for this study
Developed
Simulation
Validated
Simulation
Developed
Test Cases
Simulate
Test Cases
Evaluate
Results