Effect of Perforated Pin Fin on Thermal Performance of a Rectangular Channel in Forced Convection
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2025-04-11 |
| Journal | Journal of Information Systems Engineering & Management |
| Authors | Aamir Ali |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: High-Performance Diamond Heat Sinks
Section titled âTechnical Documentation & Analysis: High-Performance Diamond Heat SinksâExecutive Summary
Section titled âExecutive SummaryâThis research investigates advanced fin geometries for forced convection heat sinks, a critical area for high-power electronic thermal management. The findings, while based on Aluminum, directly inform the design requirements for next-generation diamond-based thermal solutions.
- Core Achievement: Validation of 12 novel fin configurations (solid, perforated, diamond, square) to maximize heat transfer effectiveness ($\eta_{eff}$) in forced convection.
- Optimal Design: The perforated diamond fin in a staggered arrangement (Design h) demonstrated superior thermal performance.
- Performance Metrics: This optimal design achieved the highest average heat transfer coefficient ($h_{av}$) of approximately 375 W/m2°C, representing a 50% augmentation over its inline counterpart.
- Mechanism: Perforations induce turbulence and increase surface area, leading to a maximum heat transfer effectiveness factor ($\eta_{eff}$) of 1.55.
- Material Limitation: The study utilized Aluminum, which has a thermal conductivity (k) of approximately 237 W/mK.
- 6CCVD Value Proposition: Replicating these optimized geometries using 6CCVDâs MPCVD diamond (k > 1000 W/mK) will yield a massive reduction in thermal resistance ($R_{th}$), enabling unprecedented cooling capacity for high-flux applications.
Technical Specifications
Section titled âTechnical Specificationsâ| Parameter | Value | Unit | Context |
|---|---|---|---|
| Optimal Heat Transfer Coefficient ($h_{av}$) | 375 | W/m2°C | Perforated diamond fin (Staggered) |
| Maximum Effectiveness Factor ($\eta_{eff}$) | 1.55 | Dimensionless | Perforated diamond fin (Staggered) |
| Nusselt Number Enhancement | 70 | % | Staggered vs. Inline perforated diamond fin |
| Reynolds Number Range (Re) | 3000 to 7000 | Dimensionless | Forced convection flow regime |
| Fin Base Length (L) | 50 | mm | Primary geometry |
| Fin Height (H) | 10 | mm | Primary geometry |
| Fin Width (w) | 2 to 4.5 | mm | Varies by arrangement |
| Lowest Fin Temperature Range Observed | 35 to 50 | °C | Staggered, perforated diamond fins |
| Fin Material Used in Study | Aluminum | N/A | Standard material for CFD simulation |
| Simulation Software | ANSYS Fluent 2023 R2 | N/A | Steady-state CFD analysis |
Key Methodologies
Section titled âKey MethodologiesâThe study employed Computational Fluid Dynamics (CFD) simulations, validated against existing experimental data, to analyze the thermal and hydraulic performance of twelve distinct fin designs.
- Modeling Environment: Steady-state simulation performed using ANSYS Fluent 2023 R2.
- Governing Physics: Reynolds-averaged Navier-Stokes (RANS) equations were applied, utilizing the k-ε turbulent model to accurately capture fluid flow and heat transmission.
- Materials: Air was used as the cooling fluid, and Aluminum was used as the solid fin material.
- Geometry Definition: A square base plate (50 mm length) was modeled, featuring 64 fins. Simulations focused on one row of 8 fins due to flow symmetry.
- Fin Designs Investigated: Twelve configurations were tested, including solid square, perforated square, solid diamond, perforated diamond, edge-perforated diamond, and hollow perforated diamond fins, arranged in both inline and staggered patterns.
- Boundary Conditions: A homogenous heat flux was applied to the heat sink base. Flow entered as fully developed with uniform velocity, operating within the Reynolds number range of 3000 to 7000.
- Validation: Numerical results for thermal resistance ($R_{th}$) were validated against experimental data from prior studies for 6.5 mm and 8 mm square fins across the tested Re range.
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThe research confirms that optimizing fin geometry and inducing turbulence are critical for thermal management. However, the ultimate performance bottleneck remains the thermal conductivity of the heat sink material itself. 6CCVD specializes in MPCVD diamond, offering the highest thermal conductivity available for engineering applications, enabling researchers to replicate and dramatically exceed the performance metrics achieved using Aluminum.
| Research Requirement/Challenge | 6CCVD Diamond Solution | Technical Advantage & Sales Driver |
|---|---|---|
| Material Upgrade for Extreme Heat Flux (Paper used Aluminum, k ≈ 237 W/mK) | Optical/Thermal Grade SCD or PCD | Diamond exhibits thermal conductivity (k) typically > 1000 W/mK (up to 2200 W/mK for SCD). Replacing Aluminum with 6CCVD diamond directly minimizes $R_{th}$ and maximizes heat spreading, essential for high-power density electronics. |
| Custom Dimensions for Scaling (50 mm base plate) | Custom PCD Plates up to 125 mm | We provide large-area Polycrystalline Diamond (PCD) wafers up to 125 mm in diameter, allowing for the scale-up of the superior staggered perforated diamond fin design for industrial applications. |
| Precision Fin Geometry & Perforations (Diamond shapes, complex holes) | Advanced Laser Cutting and Shaping | 6CCVD offers precision laser cutting services to realize the complex, high-aspect-ratio perforated and hollow fin structures (Designs g-l, k-l) identified as optimal, ensuring exact replication of CFD-optimized geometries. |
| Minimizing Friction Factor (f) (Crucial for $\eta_{eff}$ balance) | Ultra-High Quality Polishing | Our SCD material is polished to an exceptional surface roughness of Ra < 1 nm, and inch-size PCD to Ra < 5 nm. This superior finish minimizes surface shear stress, optimizing the balance between heat transfer enhancement and pressure drop (Equation 10). |
| Integration into Semiconductor Devices (High-power electronics) | Custom Metalization Services | We offer in-house deposition of standard contact metals (Au, Pt, Pd, Ti, W, Cu). This capability allows engineers to create integrated diamond heat spreaders and heat sinks with reliable electrical and thermal contacts for high-frequency or high-voltage applications. |
| Doping for Electro-Thermal Applications | Boron-Doped Diamond (BDD) | For applications requiring simultaneous thermal management and electrochemical stability (e.g., sensors or electrodes), 6CCVD supplies BDD material in thicknesses from 0.1 ”m to 500 ”m. |
Engineering Support
Section titled âEngineering Supportâ6CCVDâs in-house PhD team specializes in the thermo-physical properties of MPCVD diamond. We can assist researchers and engineers in selecting the optimal diamond grade (SCD vs. PCD) and thickness (0.1 ”m to 10 mm substrates) required to replicate or extend this Forced Convection Heat Sink research, ensuring maximum thermal efficiency and structural integrity.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
The focus of this study is to characterize the thermal behaviour of a planar heat sink with different fin patterns, namely solid, perforated, and taper fins in both inline and staggered orientations under horizontal fluid flow conditions. By using computational fluid dynamics (CFD) simulations within ANSYS software to validate the numerical model with experimental one, the study explores how adjustments to fin designs can improve heat transfer efficiency. It confirms that changes in fin profile have substantial effects on thermal performance by effectively enlarging the area for heat exchange as well as promoting turbulence. Although the study shows that increasing heat transfer area is essential, puncturing the fin structure accelerates fluid flow and enhances thermal efficiency. Overall, twelve different fin configurations, solid and perforated square fins together with diamond-shaped ones (solid & incrementally pierced on the base), edge-perforated in addition to a hollow internal rectangular cross-section of a passage, were investigated. The main objective is evaluating key performance parameters such as Nusselt number, friction factor, and heat transfer effectiveness. The results demonstrate that the higher heat transfer effectiveness factor is about 1.55 for perforated diamond fins and 1.5 for perforated fins, while the lowest value is 0.8 for solid diamond fins.