Topology Optimization, Additive Layer Manufacturing, and Experimental Testing of an Air-Cooled Heat Sink

2015 ◽  
Author(s):  
Ercan M. Dede ◽  
Shailesh N. Joshi ◽  
Feng Zhou
Keyword(s):  
Topology Optimization ◽  
Heat Sink ◽  
Computer Aided Design ◽  
Experimental Testing ◽  
Jet Impingement ◽  
Coefficient Of Performance ◽  
Air Cooling ◽  
Additive Layer Manufacturing ◽  
Cloud Data ◽  
Layer Manufacturing

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 post-processing procedure is described to synthesize water-tight solid model computer-aided design (CAD) geometry from 3-D 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 is 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 relative to the benchmark heat sink designs.

Topology Optimization, Additive Layer Manufacturing, and Experimental Testing of an Air-Cooled Heat Sink

2015 ◽  
Vol 137 (11) ◽  
Author(s):  
Ercan M. Dede ◽  
Shailesh N. Joshi ◽  
Feng Zhou
Keyword(s):  
Topology Optimization ◽  
Heat Sink ◽  
Computer Aided Design ◽  
Experimental Testing ◽  
Jet Impingement ◽  
Coefficient Of Performance ◽  
Air Cooling ◽  
Additive Layer Manufacturing ◽  
Cloud Data ◽  
Layer Manufacturing

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.

scholarly journals A Numerical and Experimental Study of a Novel Heat Sink Design for Natural Convection Cooling of LED Grow Lights

Energies ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 4046
Author(s):  
Ram Adhikari ◽  
Dawood Beyragh ◽  
Majid Pahlevani ◽  
David Wood
Keyword(s):  
Heat Transfer ◽  
Natural Convection ◽  
Heat Sink ◽  
Large Scale ◽  
High Efficiency ◽  
Experimental Testing ◽  
Growth Stages ◽  
Air Cooling ◽  
Convection Cooling ◽  
Heat Sink Design

Light-emitting diode (LED) grow lights are increasingly used in large-scale indoor farming to provide controlled light intensity and spectrum to maximize photosynthesis at various growth stages of plants. As well as converting electricity into light, the LED chips generate heat, so the boards must be properly cooled to maintain the high efficiency and reliability of the LED chips. Currently, LED grow lights are cooled by forced convection air cooling, the fans of which are often the points of failure and also consumers of a significant amount of power. Natural convection cooling is promising as it does not require any moving parts, but one major design challenge is to improve its relatively low heat transfer rate. This paper presents a novel heat sink design for natural convection cooling of LED grow lights. The new design consists of a large rectangular fin array with openings in the base transverse to the fins to increase air flow, and hence the heat transfer. Numerical simulations and experimental testing of a prototype LED grow light with the new heat sink showed that openings achieved their intended purpose. It was found that the new heat sink can transfer the necessary heat flux within the safe operating temperature range of LED chips, which is adequate for cooling LED grow lights.

scholarly journals An experimental investigation on the performance of a thermoelectric dehumidification system

2018 ◽  
Vol 12 (4) ◽  
pp. 4117-4126
Author(s):  
P. Rakkwamsuk ◽  
P. Paromupatham ◽  
K. Sathapornprasath ◽  
C. Lertsatitthanakorn ◽  
S. Soponronnarit
Keyword(s):  
Heat Sink ◽  
Cooling System ◽  
Test Chamber ◽  
Cooling Water ◽  
Suitable Condition ◽  
Cooling Capacity ◽  
Coefficient Of Performance ◽  
Air Cooling ◽  
Air Cooling System ◽  
Te Modules

A thermoelectric (TE) air-cooling system for dehumidifying indoor air in a building was investigated. The system was composed of 4 TE modules. The cold sides of the TE modules were fixed to an aluminum heat sink to remove moisture in the air of a test chamber of 1 m3 volume, while a heat sink with circulating cooling water at the hot sides of the TE modules was used for heat release. The effects of input electric current to the TE modules and air flow rate through the heat sink were experimentally determined. The system’s performance was evaluated using dehumidification effectiveness and coefficient of performance (COP). A suitable condition occurred at 18.5 A of current flow and 240 W of power being supplied to the TE modules with a corresponding cooling capacity of 149.5 W, which gave a dehumidification effectiveness of 0.62. Therefore, it is anticipated the proposed TE dehumidifier concept will contribute to the air conditioning system’s reduction of room humidity. 

SCIENTIFIC AND TECHNOLOGICAL CHALLENGES OF LAYER MANUFACTURING PROCESSES FOR POLYMER COMPONENTS PRODUCTION

2020 ◽  
Vol 8 (3) ◽  
pp. 26-31
Author(s):  
Rohit Pandey ◽  
Sandeep Salodkar
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Rapid Prototyping ◽  
Computer Aided Design ◽  
Polymer Materials ◽  
High Rate ◽  
Manufacturing Processes ◽  
Technological Parameters ◽  
Additive Layer Manufacturing ◽  
Layer Manufacturing

Purpose of study: Additive manufacturing processes taking the basic information form computer-aided design (CAD) file to convert into the stereolithography (STL) data file. Today additive layer manufacturing processes are playing a very vital role in manufacturing parts with high rate of effectiveness and accuracy. CAD software is approximated to sliced containing information of each layer by layer that is printed. The main purpose of the study is to discuss the scientific and technological challenges of additive layer manufacturing processes for making polymer components production through various technological parameters and problem-solving techniques of layer manufacturing processes. Main findings: Additive layer manufacturing is simply another name for 3D printing or rapid prototyping. As 3D printing has evolved as a technology, it has moved beyond prototyping and into the manufacturing space, with small runs of finished components now being produced by 3D printing machines around the world. Additive layer manufacturing (ALM) is the opposite of subtractive manufacturing, in which material is removed to reach the desired shape Methodology Used:  The continuous and increasing growth of additive layer manufacturing processes to discuss with different experimental behavior through simulations and graphical representations. In ALM, 3D parts are built up in successive layers of material under computer control. In its early days, 3D printing was used mainly for rapid prototyping, but it is now frequently used to make finished parts the automotive and aerospace sectors, amongst many others. The originality of study: At the present time, the technologies of additive manufacturing are not just using for making models with the plastics but using polymer materials. It is possible to make finished products developed with high accuracy and save a lot of time and there is the possibility of testing more models.

Bridging between topology optimization and additive manufacturing via Laplacian smoothing

2021 ◽  
pp. 1-12
Author(s):  
Bruno Barroqueiro ◽  
A. Andrade-Campos ◽  
J. Dias-de-Oliveira ◽  
R.A.F. Valente
Keyword(s):  
Topology Optimization ◽  
Structural Changes ◽  
Volume Constraint ◽  
Mesh Quality ◽  
Additive Layer Manufacturing ◽  
Advantages And Disadvantages ◽  
Geometrical Features ◽  
Layer Manufacturing ◽  
Laplacian Smoothing ◽  
And Performance

Abstract The potential of Additive Layer Manufacturing (ALM) is high, with a whole new set of manufacturable parts with unseen complexity being offered. Moreover, the combination of Topology Optimization (TO) with ALM has brought mutual advantages. However, the transition between TO and ALM is a non-trivial step that requires a robust methodology. Thus, the purpose of this work is to evaluate the capabilities of adopting the commonly used Laplacian smoothing methodology as the bridging tool between TO and ALM. Several algorithms are presented and compared in terms of efficiency and performance. Most importantly, a different concept of Laplacian smoothing is presented as well as a set of metrics to evaluate the performance of the algorithms, with the advantages and disadvantages of each algorithm being discussed. In the end, the proposed mutable diffusion Laplacian algorithm is presented and exhibits less volume shrinkage and shows better preservation of some geometrical features such as thin members and edges. Moreover, a new volume constraint is presented, decreasing the resulting structural changes in the presented geometry and improving the final mesh quality.

scholarly journals A Comprehensive Review of Isogeometric Topology Optimization: Methods, Applications and Prospects

2020 ◽  
Vol 33 (1) ◽  
Author(s):  
Jie Gao ◽  
Mi Xiao ◽  
Yan Zhang ◽  
Liang Gao
Keyword(s):  
Topology Optimization ◽  
Computer Aided Design ◽  
Numerical Technique ◽  
Optimization Methods ◽  
Negative Influence ◽  
Comprehensive Overview ◽  
Promising Alternative ◽  
Computer Aided ◽  
Optimal Material ◽  
Material Layout

AbstractTopology Optimization (TO) is a powerful numerical technique to determine the optimal material layout in a design domain, which has accepted considerable developments in recent years. The classic Finite Element Method (FEM) is applied to compute the unknown structural responses in TO. However, several numerical deficiencies of the FEM significantly influence the effectiveness and efficiency of TO. In order to eliminate the negative influence of the FEM on TO, IsoGeometric Analysis (IGA) has become a promising alternative due to its unique feature that the Computer-Aided Design (CAD) model and Computer-Aided Engineering (CAE) model can be unified into a same mathematical model. In the paper, the main intention is to provide a comprehensive overview for the developments of Isogeometric Topology Optimization (ITO) in methods and applications. Finally, some prospects for the developments of ITO in the future are also presented.

scholarly journals Analytical Investigation of a Novel System for Combined Dew Point Cooling and Water Recovery

2021 ◽  
Vol 11 (4) ◽  
pp. 1481
Author(s):  
Aleksandra Cichoń ◽  
William Worek
Keyword(s):  
Energy Consumption ◽  
Convective Heat Transfer Coefficient ◽  
Specific Energy Consumption ◽  
Analytical Investigation ◽  
Dew Point ◽  
Energy Utilization ◽  
Coefficient Of Performance ◽  
Air Cooling ◽  
Water Recovery ◽  
Utilization Factor

This paper presents the analytical investigation of a novel system for combined Dew Point Cooling and Water Recovery (DPC-WR system). The operating principle of the presented system is to utilize the dew point cooling phenomenon implemented in two stages in order to obtain both air cooling and water recovery. The system performance is described by different indicators, including the coefficient of performance (COP), gained output ratio (GOR), energy utilization factor (EUF), specific energy consumption (SEC) and specific daily water production (SDWP). The performance indicators are calculated for various climatic zones using a validated analytical model based on the convective heat transfer coefficient. By utilizing the dew point cooling phenomenon, it is possible to minimize the heat and electric energy consumption from external sources, which results in the COP and GOR values being an order of magnitude higher than for other cooling and water recovery technologies. The EUF value of the DPC-WR system ranges from 0.76 to 0.96, with an average of 0.90. The SEC value ranges from 0.5 to 2.0 kWh/m3 and the SDWP value ranges from 100 to 600 L/day/(kg/s). In addition, the DPC-WR system is modular, i.e., it can be multiplied as needed to achieve the required cooling or water recovery capacity.

Product Model Preparation and Processing for Micromanufacturing

2008 ◽  
Vol 8 (2) ◽  
Author(s):  
Chao-Yaug Liao ◽  
Jean-Claude Léon ◽  
Cédric Masclet ◽  
Michel Bouriau ◽  
Patrice L. Baldeck ◽  
...  
Keyword(s):  
Laser Beam ◽  
Computer Aided Design ◽  
Welding Process ◽  
Product Model ◽  
Processing Scheme ◽  
Proposed Model ◽  
Layer Manufacturing ◽  
Manifold Models ◽  
Model Preparation ◽  
Aided Design

Based on the two-photon polymerization technique, an analysis of product shapes is performed so that their digital manufacturing models can be efficiently processed for micromanufacture. To describe microstructures, this analysis shows that nonmanifold models are of interest. These models can be intuitively understood as combinations of wires, surfaces, and volumes. Minimum acceptable wall thickness, wire dimension, and laser density of energy are among the elements justifying this category of models. Taking into account this requirement, a model preparation and processing scheme is proposed that widens the laser beam trajectories with a concept of extended layer manufacturing technique. A tessellation process suited for non-manifold models has been developed for computer-aided design models imported from standard for the exchange of product files. After tessellation, several polyhedral subdomains form a nonmanifold polyhedron. To plan the trajectories of the laser beam, adaptive slicing and global 3D hatching processes as well as a “welding” process (for joining subdomains of different dimensionality) have been combined. Finally, two nonmanifold microstructures are fabricated according to the proposed model preparation and processing scheme.

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