ABSTRACT
To enhance the hydrothermal performance of cold plates, this study constructs a topology optimization framework that integrates conjugate heat transfer principles, aiming to maximize heat generation and minimize fluid flow dissipation. The robustness of the design is improved through the application of projection and density filtering techniques, with the projection intensity value incrementally increased via a parameter scanning method to bolster numerical convergence. The inlet and outlet distribution of the cold plate, aligned along its centerline, is determined through various target weight combinations, generating clear, continuous layouts. To further substantiate the effectiveness of the optimized configuration, a topology optimization design employing an objective function weighting factor of 0.7:0.3 is chosen to create the three-dimensional geometry of the cold plate. A parallel flow channel design, maintaining an identical fluid volume fraction and heat transfer boundary length, is introduced for comparative analysis. Moreover, performance indices such as surface temperature, pressure drop across the channel, average Nusselt number, and thermal resistance are assessed for two cold plates under varying inlet velocities. Both simulations and experiments indicate that the hydrothermal performance of the developed topological structure significantly surpasses that of the conventional parallel channel design, a disparity that amplifies with increasing inlet velocities.
KEYWORDS
PAPER SUBMITTED: 2024-03-24
PAPER REVISED: 2024-07-14
PAPER ACCEPTED: 2024-07-22
PUBLISHED ONLINE: 2024-08-31
- Gong, Z., et al., A Study of the Effects of the Micro-channel Cold Plate on the Cooling Performance of Battery Thermal Management Systems, Thermal Science, 26 (2022), 2B, pp. 1503-1517
- Farhan, M., et al., Design and Analysis of Liquid Cooling Plates for Different Flow Channel Configurations, Thermal Science, 26 (2022), 2B, pp. 1463-1475
- Xia, Y., et al., Numerical Investigation of Microchannel Heat Sinks with Different Inlets and Outlets Based on Topology Optimization, Applied Energy, 330 (2023), pp. 120335
- Wang, J., et al., Study of the Influence of Objective Functions on the Topology Optimization Design of Battery Cold Plate, Applied Thermal Engineering, 226 (2023), PP. 120326
- Matsumori, T., et al., Topology Optimization for Fluid-thermal Interaction Problems under Constant Input Power, Structural and Multidisciplinary Optimization, 47 (2013), 4, pp. 571-581
- Sato, Y., et al., An Optimum Design Method for a Thermal-fluid Device Incorporating Multi-objective Topology Optimization with an Adaptive Weighting Scheme, Journal of Mechanical Design, 140 (2018), 3, pp. 031402
- Zhao, X., et al., A "Poor Man's Approach" to Topology Optimization of Cooling Channels Based on a Darcy Flow Model, International Journal of Heat and Mass Transfer, 116 (2018), pp. 1108-1123
- Liu, W., et al., Micro-channel Topology Optimization Based on Enhanced Heat Transfer Mechanism, Thermal Science, 28 (2024), 1B, pp. 611-626
- Li, H., et al., Experimental and Numerical Investigation of Fluid Cooling Channel Layout Designed by Topology Optimization, Journal of Mechanical Engineering, 55 (2019), 10, pp. 198-206
- Zhang, T., et al., Topology Optimization of Regenerative Cooling Channel in Non-uniform Thermal Environment of Hypersonic Engine, Applied Thermal Engineering, 219 (2023), pp. 119384
- Haertel, et al., Topology Optimization of a Pseudo 3D Thermofluid Heat Sink Model, International Journal of Heat and Mass Transfer, 121 (2018), pp. 1073-1088
- Yaji, K., et al., A Topology Optimization Method for a Coupled Thermal-fluid Problem using Level Set Boundary Expressions, International Journal of Heat and Mass Transfer, 81 (2015), pp. 878-888
- Pei, Y., et al., Research on Air-cooled Heat Sink Based on Topology Optimization, Journal of Mechanical Engineering, 56 (2020), 16, pp. 91-97
- Long, K., et al., Multi-material Topology Optimization for the Transient Heat Conduction Problem using a Sequential Quadratic Programming Algorithm, Engineering Optimization, 50 (2018), 12, pp. 2091-2107
- Li, X., et al., Multi-material Topology Optimization of Transient Heat Conduction Structure with Functional Gradient Constraint, International Communications in Heat and Mass Transfer, 131 (2022), pp. 105845
- Zhou, J., et al., Thermal Design of Microchannel Heat Sinks using a Contour Extraction Based on Topology Optimization (CEBTO) Method, International Journal of Heat and Mass Transfer, 189 (2022), pp. 122703
- Mo, X., et al., Topology Optimization of Cooling Plates for Battery Thermal Management, International Journal of Heat and Mass Transfer, 178 (2021), pp. 121612
- Guest, J. K., Prevost, J. H., Topology Optimization of Creeping Fluid Flows using a Darcy-Stokes Finite Element, International Journal for Numerical Methods in Engineering, 66 (2006), 3, pp. 461-484
- Liu, Z., et al., Numerical Analysis of Topology-optimized Cold Plates for Thermal Management of Battery Packs, Applied Thermal Engineering, 238 (2024), pp. 121983
- Kobayashi, H., et al., Topology Design of Two-fluid Heat Exchange, Structural and Multidisciplinary Optimization, 63 (2021), pp. 821-834
- Lazarov, B. S., Sigmund, O., Filters in Topology Optimization Based on Helmholtz-type Differential Equations, International Journal for Numerical Methods in Engineering, 86 (2011), 6, pp. 765-781
- Wang, F., et al., On Projection Methods, Convergence and Robust Formulations in Topology Optimization, Structural and Multidisciplinary Optimization, 43 (2011), 6, pp. 767-784
- COMSOL Multiphysics 5.4, COMSOL Inc., cn.comsol.com/products
- Schenk, O., Gartner, K., Solving Unsymmetric Sparse Systems of Linear Equations with PARDISO, Future Generation Computer Systems, 20 (2004), 3, pp. 475-487
- Svanberg, K., The Method of Moving Asymptotes—A New Method for Structural Optimization, International Journal for Numerical Methods in Engineering, 24 (1987), 2, pp. 359-373
- Koga, A., et al., Development of Heat Sink Device by Using Topology Optimization, International Journal of Heat and Mass Transfer, 64 (2013), pp. 759-772