Abstract:
This study presents a comprehensive computational investigation into the thermal performance of pin-fin heat sinks using advanced simulation tools—CATIA for precise geometric modelling and ANSYS Fluent for robust computational fluid dynamics (CFD) simulations. The primary objective is to evaluate how critical geometrical parameters—fin diameter, fin spacing, and fin height—affect key thermal and flow performance indicators such as heat transfer coefficient (HTC), Nusselt number (Nu), pressure drop, friction factor, and Performance Evaluation Criteria (PEC). By simulating different configurations and analysing their outcomes, the research aims to identify optimal design combinations that can significantly enhance the efficiency of heat sinks while reducing flow resistance, a factor crucial for improving the overall performance of cooling systems across industrial and electronic applications.
The simulation findings highlight the importance of geometric optimization in thermal management. Smaller fin diameters (e.g., 3 mm) yielded superior heat transfer characteristics, with increased HTC and Nu values compared to larger diameters. Similarly, tighter fin spacing contributed to more effective thermal performance by promoting higher convective heat transfer. Increases in fin height also boosted heat transfer, with a measurable 20% improvement in the heat transfer rate, though this benefit came at the cost of increased pressure drop. After evaluating various design iterations, the configuration consisting of 3 mm fin diameter, 7 mm fin height, and 4 mm spacing emerged as the most balanced and efficient, offering enhanced thermal performance while maintaining manageable flow resistance. This result underscores the need to weigh thermal gains against pressure penalties when designing pin-fin heat sinks.
Validation of the CFD outcomes was carried out through comparative analysis with existing experimental and computational studies. The consistency between the simulation results and previously reported data confirms the reliability and accuracy of the numerical methods applied. This validation strengthens the credibility of the design recommendations put forth in the study. Ultimately, the research provides a valuable framework for the systematic optimisation of pin-fin heat sinks, offering engineers and designers practical insights into enhancing heat dissipation. These findings have broad implications for industries relying on compact and high-efficiency cooling solutions, such as electronics, automotive, and energy systems, where thermal management is a key performance driver.
Aim :
The primary aim of this study is to improve the heat dissipation efficiency of pin-fin heat sinks by systematically optimising their geometric characteristics, including the number, arrangement, and diameter of the fins. Using advanced simulation tools, the research investigates how each of these parameters influences key thermal performance metrics such as heat transfer coefficient, Nusselt number, and pressure drop. Through a comparative analysis of various configurations, the study identifies the optimal combination that delivers the best balance between enhanced thermal conductivity and minimal flow resistance. This optimisation not only improves the overall performance of the cooling system but also provides valuable design guidelines for applications where efficient heat management is critical, such as in electronics, automotive, and industrial thermal systems..
Objectives:
This study begins with an in-depth review of previous research on pin-fin heat exchangers, focusing on how different geometrical configurations influence thermal performance. By analyzing established findings, the study identifies key parameters—such as fin number, diameter, and spacing—that significantly affect heat transfer and pressure drop. The review also includes an examination of simulation validation techniques, such as mesh convergence studies and comparisons with experimental data, to ensure the credibility and accuracy of the computational fluid dynamics (CFD) simulations. Understanding these foundational methodologies allows the current work to build upon proven strategies and adopt reliable simulation practices, setting a solid groundwork for further analysis.
The core of the study involves systematically investigating how changes in the number, diameter, and spacing of pin fins impact the performance of a heat exchanger. Increasing the number of fins can enhance surface area and improve heat transfer but may lead to higher flow resistance. Similarly, adjusting fin diameter affects both the contact area for heat exchange and the obstruction to airflow. Fin spacing plays a crucial role in determining flow distribution and thermal boundary layer development. By simulating various configurations using tools like CATIA for modeling and ANSYS Fluent for CFD analysis, the study compares each setup based on thermal efficiency metrics such as heat transfer coefficient, Nusselt number, and pressure drop. The ultimate objective is to identify the optimal combination of geometric parameters that yields the best thermal performance with minimal energy loss, contributing to the development of more effective and energy-efficient heat sink designs.
