Large scale three-dimensional topology optimisation of heat sinks cooled by natural convection

This work presents the application of density-based topology optimisation to the design of three-dimensional heat sinks cooled by natural convection. The governing equations are the steady-state incompressible Navier-Stokes equations coupled to the thermal convection-diffusion equation through the Bousinessq approximation. The fully coupled non-linear multiphysics system is solved using stabilised trilinear equal-order finite elements in a parallel framework allowing for the optimisation of large scale problems with order of 40-330 million state degrees of freedom. The flow is assumed to be laminar and several optimised designs are presented for Grashof numbers between $10^3$ and $10^6$. Interestingly, it is observed that the number of branches in the optimised design increases with increasing Grashof numbers, which is opposite to two-dimensional optimised designs.Comment: Submitted (18th of August 2015

A "poor man's" approach to topology optimization of natural convection problems

Topology optimization of natural convection problems is computationally expensive, due to the large number of degrees of freedom (DOFs) in the model and its two-way coupled nature. Herein, a method is presented to reduce the computational effort by use of a reduced-order model governed by simplified physics. The proposed method models the fluid flow using a potential flow model, which introduces an additional fluid property. This material property currently requires tuning of the model by comparison to numerical Navier-Stokes based solutions. Topology optimization based on the reduced-order model is shown to provide qualitatively similar designs, as those obtained using a full Navier-Stokes based model. The number of DOFs is reduced by 50% in two dimensions and the computational complexity is evaluated to be approximately 12.5% of the full model. We further compare to optimized designs obtained utilizing Newton's convection law.Comment: Preprint version. Please refer to final version in Structural Multidisciplinary Optimization https://doi.org/10.1007/s00158-019-02215-

A "poor man's" approach for high-resolution three-dimensional topology optimization of natural convection problems

This paper treats topology optimization of natural convection problems. A simplified model is suggested to describe the flow of an incompressible fluid in steady state conditions, similar to Darcy's law for fluid flow in porous media. The equations for the fluid flow are coupled to the thermal convection-diffusion equation through the Boussinesq approximation. The coupled non-linear system of equations is discretized with stabilized finite elements and solved in a parallel framework that allows for the optimization of high resolution three-dimensional problems. A density-based topology optimization approach is used, where a two-material interpolation scheme is applied to both the permeability and conductivity of the distributed material. Due to the simplified model, the proposed methodology allows for a significant reduction of the computational effort required in the optimization. At the same time, it is significantly more accurate than even simpler models that rely on convection boundary conditions based on Newton's law of cooling. The methodology discussed herein is applied to the optimization-based design of three-dimensional heat sinks. The final designs are formally compared with results of previous work obtained from solving the full set of Navier-Stokes equations. The results are compared in terms of performance of the optimized designs and computational cost. The computational time is shown to be decreased to around 5-20% in terms of core-hours, allowing for the possibility of generating an optimized design during the workday on a small computational cluster and overnight on a high-end desktop

Topology optimisation of natural convection problems

This paper demonstrates the application of the density-based topology optimisation approach for the design of heat sinks and micropumps based on natural convection effects. The problems are modelled under the assumptions of steady-state laminar flow using the incompressible Navier-Stokes equations coupled to the convection-diffusion equation through the Boussinesq approximation. In order to facilitate topology optimisation, the Brinkman approach is taken to penalise velocities inside the solid domain and the effective thermal conductivity is interpolated in order to accommodate differences in thermal conductivity of the solid and fluid phases. The governing equations are discretised using stabilised finite elements and topology optimisation is performed for two different problems using discrete adjoint sensitivity analysis. The study shows that topology optimisation is a viable approach for designing heat sink geometries cooled by natural convection and micropumps powered by natural convection.Comment: Submitted to the 'International Journal for Numerical Methods in Fluids' on 28th of August 2013 - currently under revie

Performance assessment of density and level-set topology optimisation methods for 3D heatsink design

In this paper, two most prevalent topological optimisation approaches namely Density and Level set method are applied to a three dimensional heatsink design problem. The relative performance of the two approaches are compared in terms of design quality, robustness and computational speed. The work is original as for the first time it demonstrates the relative advantages and disadvantages for each method when applied to a practical engineering problem. It is additionally novel in that it presents the design of a convectively cooled heatsink by solving full thermo-fluid equations for two different solid-fluid material sets. Further, results are validated using a separate CFD study with the optimised designs are compared against a standard pin-fin based heatsink design. The results show that the Density method demonstrates better performance in terms of robustness and computational speed, while Level-set method yields a better quality design

Topology Optimization of a Pseudo 3D Thermofluid Heat Sink Model

This paper investigates the application of density-based topology optimization to the design of air-cooled forced convection heat sinks. To reduce the computational burden that is associated with a full 3D optimization, a pseudo 3D optimization model comprising a 2D modeled conducting metal base layer and a thermally coupled 2D modeled thermofluid design layer is used. Symmetry conditions perpendicular to the flow direction are applied to generate periodic heat sink designs. The optimization objective is to minimize the heat sink heat transfer resistance for a fixed pressure drop over the heat sink and a fixed heat production rate in the base plate. Optimized designs are presented and the resulting fin geometry is discussed from a thermal engineering point of view and compared to fin shapes resulting from a pressure drop minimization objective. Parametric studies are conducted to analyze the influence of the pressure drop on the heat sink heat transfer resistance. To quantify the influence of the assumptions made in the pseudo 3D optimization model, validation simulations with a body-fitted mesh in 2D and 3D are conducted. A good agreement between optimization model and validation simulations is found, confirming the physical validity of the utilized optimization model. Two topology optimized designs are exemplarily benchmarked against a size optimized parallel fin heat sink and an up to 13.6% lower thermal resistance is found to be realized by the topology optimization