Performance validation of microchannel heat sinks based on single/multiobjective topology optimization and manufactured by selective laser melting
This study presents the design and experimental validation of two-dimensional (2D) and pseudo three-dimensional (P3D) microchannel heat sinks optimized through single-objective and multiobjective topology optimization via the solid isotropic material with penalization (SIMP) method. The optimization...
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Elsevier
2025-10-01
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| Series: | Case Studies in Thermal Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2214157X2501127X |
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| author | Guangzhao Yang Mingxuan Cao Pingnan Huang Linlin Pan Xin Zhong Liang Yang Weiwei Guo Matthew M.F. Yuen Huijun Li |
| author_facet | Guangzhao Yang Mingxuan Cao Pingnan Huang Linlin Pan Xin Zhong Liang Yang Weiwei Guo Matthew M.F. Yuen Huijun Li |
| author_sort | Guangzhao Yang |
| collection | DOAJ |
| description | This study presents the design and experimental validation of two-dimensional (2D) and pseudo three-dimensional (P3D) microchannel heat sinks optimized through single-objective and multiobjective topology optimization via the solid isotropic material with penalization (SIMP) method. The optimization objectives were to maximize the heat transfer efficiency and minimize the pressure drop, aiming for a balanced thermal performance. Microchannel heat sinks were fabricated via selective laser melting (SLM), and thermal performance and flow resistance were measured. The results showed that the P3D multiobjective topology optimization model (P3D-MOTO) is superior to other models. When the flow rate increased from 20 ml/min to 80 ml/min, P3D-MOTO significantly reduced the temperature by 8.9 °C while maintaining a low pressure drop, demonstrating excellent performance. Compared with conventional microchannel heat sinks, the P3D-MOTO is 10.3 °C cooler at high flow rates and offers an optimal balance between increased heat transfer efficiency and reduced flow resistance. The performance evaluation criterion (PEC) value of P3D-MOTO increased from 1.19 to 1.46 as the flow rate increased, indicating superior overall performance. This study confirms that the P3D-MOTO provides efficient and energy-saving thermal management solutions, while emphasizing that the integration of topology optimization with SLM can create complex geometries, thereby enhancing thermal performance. |
| format | Article |
| id | doaj-art-91f2f99607a84a53bca7fd44851040f8 |
| institution | Kabale University |
| issn | 2214-157X |
| language | English |
| publishDate | 2025-10-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Case Studies in Thermal Engineering |
| spelling | doaj-art-91f2f99607a84a53bca7fd44851040f82025-08-20T03:36:53ZengElsevierCase Studies in Thermal Engineering2214-157X2025-10-017410686710.1016/j.csite.2025.106867Performance validation of microchannel heat sinks based on single/multiobjective topology optimization and manufactured by selective laser meltingGuangzhao Yang0Mingxuan Cao1Pingnan Huang2Linlin Pan3Xin Zhong4Liang Yang5Weiwei Guo6Matthew M.F. Yuen7Huijun Li8School of Mechanical and Automation Engineering, Wuyi University, Jiangmen, 529020, ChinaSchool of Mechanical and Automation Engineering, Wuyi University, Jiangmen, 529020, China; Jiangmen Key Laboratory of Polymer Intelligent Manufacturing, Jiangmen, 529020, China; Corresponding author.School of Mechanical and Automation Engineering, Wuyi University, Jiangmen, 529020, China.School of Mechatronic Engineering and Automation, Foshan University, Foshan, 528225, China; Corresponding author.School of Mechanical and Automation Engineering, Wuyi University, Jiangmen, 529020, ChinaSchool of Mechanical and Automation Engineering, Wuyi University, Jiangmen, 529020, ChinaSchool of Mechanical and Automation Engineering, Wuyi University, Jiangmen, 529020, ChinaSchool of Mechanical and Automation Engineering, Wuyi University, Jiangmen, 529020, ChinaDepartment of Mechanical Engineering, Hong Kong University of Science and Technology, 999077, Hong Kong, ChinaSchool of Mechanical and Automation Engineering, Wuyi University, Jiangmen, 529020, China; School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Northfields Ave, Wollongong, NSW, 2522, AustraliaThis study presents the design and experimental validation of two-dimensional (2D) and pseudo three-dimensional (P3D) microchannel heat sinks optimized through single-objective and multiobjective topology optimization via the solid isotropic material with penalization (SIMP) method. The optimization objectives were to maximize the heat transfer efficiency and minimize the pressure drop, aiming for a balanced thermal performance. Microchannel heat sinks were fabricated via selective laser melting (SLM), and thermal performance and flow resistance were measured. The results showed that the P3D multiobjective topology optimization model (P3D-MOTO) is superior to other models. When the flow rate increased from 20 ml/min to 80 ml/min, P3D-MOTO significantly reduced the temperature by 8.9 °C while maintaining a low pressure drop, demonstrating excellent performance. Compared with conventional microchannel heat sinks, the P3D-MOTO is 10.3 °C cooler at high flow rates and offers an optimal balance between increased heat transfer efficiency and reduced flow resistance. The performance evaluation criterion (PEC) value of P3D-MOTO increased from 1.19 to 1.46 as the flow rate increased, indicating superior overall performance. This study confirms that the P3D-MOTO provides efficient and energy-saving thermal management solutions, while emphasizing that the integration of topology optimization with SLM can create complex geometries, thereby enhancing thermal performance.http://www.sciencedirect.com/science/article/pii/S2214157X2501127XMicrochannel heat sinkTopology optimizationSelective laser meltingMultiobjectivePseudo three-dimensional modelThermal management |
| spellingShingle | Guangzhao Yang Mingxuan Cao Pingnan Huang Linlin Pan Xin Zhong Liang Yang Weiwei Guo Matthew M.F. Yuen Huijun Li Performance validation of microchannel heat sinks based on single/multiobjective topology optimization and manufactured by selective laser melting Case Studies in Thermal Engineering Microchannel heat sink Topology optimization Selective laser melting Multiobjective Pseudo three-dimensional model Thermal management |
| title | Performance validation of microchannel heat sinks based on single/multiobjective topology optimization and manufactured by selective laser melting |
| title_full | Performance validation of microchannel heat sinks based on single/multiobjective topology optimization and manufactured by selective laser melting |
| title_fullStr | Performance validation of microchannel heat sinks based on single/multiobjective topology optimization and manufactured by selective laser melting |
| title_full_unstemmed | Performance validation of microchannel heat sinks based on single/multiobjective topology optimization and manufactured by selective laser melting |
| title_short | Performance validation of microchannel heat sinks based on single/multiobjective topology optimization and manufactured by selective laser melting |
| title_sort | performance validation of microchannel heat sinks based on single multiobjective topology optimization and manufactured by selective laser melting |
| topic | Microchannel heat sink Topology optimization Selective laser melting Multiobjective Pseudo three-dimensional model Thermal management |
| url | http://www.sciencedirect.com/science/article/pii/S2214157X2501127X |
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