Investment casting and experimental testing of heat sinks designed by topology optimization

Tian Lei, Joe Alexandersen, Boyan Stefanov Lazarov, Fengwen Wang, Jan Hendrik Klaas Haertel, Simone Sanna, Ole Sigmund, Kurt Engelbrecht*

*Corresponding author for this work

Research output: Contribution to journalJournal articleResearchpeer-review

Abstract

Topology optimization (TO) is an attractive numerical tool to obtain optimized engineering designs, which has been originally developed for mechanical optimization and extended to the area of conjugate heat transfer. With rapid developments in topology optimization models, promising designs have been proposed and presented recently for conjugate heat transfer problems. However, only a very small number of experimental validations of TO heat transfer devices have been reported. In this paper, investment casting (IC) using 3D stereolithography (SLA) printed patterns is proposed to fabricate 3D metal heat transfer devices designed by TO. Three heat sinks for natural convection are designed by a previously reported topology optimization model and five reference pin-fin heat sinks are devised for comparison. From those designs six heat sinks are cast in Britannia metal, fully reproducing the complex 3D optimized designs. It shows that SLA-assisted IC is a very promising technology with low cost and high accuracy for fabricating TO metal parts, which is not limited to heat transfer devices and can be extended to other areas such as structural optimization. A natural convection experimental setup is used to experimentally study the performance of the fabricated heat sinks. The results show that the tested TO heat sinks can always realize the best heat dissipation performance compared to pin-fin heat sinks, when operating under the conditions used for the optimization. Moreover, validation simulations have been conducted to investigate the temperature distribution, fluid flow pattern and local heat transfer coefficient for the TO and pin-fin designs, further evidencing that TO designs always perform better under the design conditions. In addition, the impact of heat sink orientation and radiation are presented.
Original languageEnglish
JournalInternational Journal of Heat and Mass Transfer
Volume127
Pages (from-to)396-412
Number of pages17
ISSN0017-9310
DOIs
Publication statusPublished - 2018

Keywords

  • Topology optimization
  • Heat sink
  • Natural convection
  • Investment casting
  • Stereolithography printing
  • Experimental test

Cite this

@article{8ce092c3887643d59174366e95708016,
title = "Investment casting and experimental testing of heat sinks designed by topology optimization",
abstract = "Topology optimization (TO) is an attractive numerical tool to obtain optimized engineering designs, which has been originally developed for mechanical optimization and extended to the area of conjugate heat transfer. With rapid developments in topology optimization models, promising designs have been proposed and presented recently for conjugate heat transfer problems. However, only a very small number of experimental validations of TO heat transfer devices have been reported. In this paper, investment casting (IC) using 3D stereolithography (SLA) printed patterns is proposed to fabricate 3D metal heat transfer devices designed by TO. Three heat sinks for natural convection are designed by a previously reported topology optimization model and five reference pin-fin heat sinks are devised for comparison. From those designs six heat sinks are cast in Britannia metal, fully reproducing the complex 3D optimized designs. It shows that SLA-assisted IC is a very promising technology with low cost and high accuracy for fabricating TO metal parts, which is not limited to heat transfer devices and can be extended to other areas such as structural optimization. A natural convection experimental setup is used to experimentally study the performance of the fabricated heat sinks. The results show that the tested TO heat sinks can always realize the best heat dissipation performance compared to pin-fin heat sinks, when operating under the conditions used for the optimization. Moreover, validation simulations have been conducted to investigate the temperature distribution, fluid flow pattern and local heat transfer coefficient for the TO and pin-fin designs, further evidencing that TO designs always perform better under the design conditions. In addition, the impact of heat sink orientation and radiation are presented.",
keywords = "Topology optimization, Heat sink, Natural convection, Investment casting, Stereolithography printing, Experimental test",
author = "Tian Lei and Joe Alexandersen and Lazarov, {Boyan Stefanov} and Fengwen Wang and Haertel, {Jan Hendrik Klaas} and Simone Sanna and Ole Sigmund and Kurt Engelbrecht",
year = "2018",
doi = "10.1016/j.ijheatmasstransfer.2018.07.060",
language = "English",
volume = "127",
pages = "396--412",
journal = "International Journal of Heat and Mass Transfer",
issn = "0017-9310",
publisher = "Pergamon Press",

}

Investment casting and experimental testing of heat sinks designed by topology optimization. / Lei, Tian; Alexandersen, Joe; Lazarov, Boyan Stefanov; Wang, Fengwen; Haertel, Jan Hendrik Klaas; Sanna, Simone; Sigmund, Ole; Engelbrecht, Kurt.

In: International Journal of Heat and Mass Transfer, Vol. 127, 2018, p. 396-412.

Research output: Contribution to journalJournal articleResearchpeer-review

TY - JOUR

T1 - Investment casting and experimental testing of heat sinks designed by topology optimization

AU - Lei, Tian

AU - Alexandersen, Joe

AU - Lazarov, Boyan Stefanov

AU - Wang, Fengwen

AU - Haertel, Jan Hendrik Klaas

AU - Sanna, Simone

AU - Sigmund, Ole

AU - Engelbrecht, Kurt

PY - 2018

Y1 - 2018

N2 - Topology optimization (TO) is an attractive numerical tool to obtain optimized engineering designs, which has been originally developed for mechanical optimization and extended to the area of conjugate heat transfer. With rapid developments in topology optimization models, promising designs have been proposed and presented recently for conjugate heat transfer problems. However, only a very small number of experimental validations of TO heat transfer devices have been reported. In this paper, investment casting (IC) using 3D stereolithography (SLA) printed patterns is proposed to fabricate 3D metal heat transfer devices designed by TO. Three heat sinks for natural convection are designed by a previously reported topology optimization model and five reference pin-fin heat sinks are devised for comparison. From those designs six heat sinks are cast in Britannia metal, fully reproducing the complex 3D optimized designs. It shows that SLA-assisted IC is a very promising technology with low cost and high accuracy for fabricating TO metal parts, which is not limited to heat transfer devices and can be extended to other areas such as structural optimization. A natural convection experimental setup is used to experimentally study the performance of the fabricated heat sinks. The results show that the tested TO heat sinks can always realize the best heat dissipation performance compared to pin-fin heat sinks, when operating under the conditions used for the optimization. Moreover, validation simulations have been conducted to investigate the temperature distribution, fluid flow pattern and local heat transfer coefficient for the TO and pin-fin designs, further evidencing that TO designs always perform better under the design conditions. In addition, the impact of heat sink orientation and radiation are presented.

AB - Topology optimization (TO) is an attractive numerical tool to obtain optimized engineering designs, which has been originally developed for mechanical optimization and extended to the area of conjugate heat transfer. With rapid developments in topology optimization models, promising designs have been proposed and presented recently for conjugate heat transfer problems. However, only a very small number of experimental validations of TO heat transfer devices have been reported. In this paper, investment casting (IC) using 3D stereolithography (SLA) printed patterns is proposed to fabricate 3D metal heat transfer devices designed by TO. Three heat sinks for natural convection are designed by a previously reported topology optimization model and five reference pin-fin heat sinks are devised for comparison. From those designs six heat sinks are cast in Britannia metal, fully reproducing the complex 3D optimized designs. It shows that SLA-assisted IC is a very promising technology with low cost and high accuracy for fabricating TO metal parts, which is not limited to heat transfer devices and can be extended to other areas such as structural optimization. A natural convection experimental setup is used to experimentally study the performance of the fabricated heat sinks. The results show that the tested TO heat sinks can always realize the best heat dissipation performance compared to pin-fin heat sinks, when operating under the conditions used for the optimization. Moreover, validation simulations have been conducted to investigate the temperature distribution, fluid flow pattern and local heat transfer coefficient for the TO and pin-fin designs, further evidencing that TO designs always perform better under the design conditions. In addition, the impact of heat sink orientation and radiation are presented.

KW - Topology optimization

KW - Heat sink

KW - Natural convection

KW - Investment casting

KW - Stereolithography printing

KW - Experimental test

U2 - 10.1016/j.ijheatmasstransfer.2018.07.060

DO - 10.1016/j.ijheatmasstransfer.2018.07.060

M3 - Journal article

VL - 127

SP - 396

EP - 412

JO - International Journal of Heat and Mass Transfer

JF - International Journal of Heat and Mass Transfer

SN - 0017-9310

ER -