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Abstract This paper proposes a computational fluid dynamics (CFD) simulation methodology for the multi-design variable optimization of heat sinks for natural convection single-phase immersion cooling of high power-density Data Center server electronics. Immersion cooling provides the capability to cool higher power-densities than air cooling. Due to this, retrofitting Data Center servers initially designed for air-cooling for immersion cooling is of interest. A common area of improvement is in optimizing the air-cooled component heat sinks for the fluid and thermal properties of liquid cooling dielectric fluids. Current heat sink optimization methodologies for immersion cooling demonstrated within the literature rely on a server-level optimization approach. This paper proposes a server-agnostic approach to immersion cooling heat sink optimization by developing a heat sink-level CFD to generate a dataset of optimized heat sinks for a range of variable input parameters: inlet fluid temperature, power dissipation, fin thickness, and number of fins. The objective function of optimization is minimizing heat sink thermal resistance. This research demonstrates an effective modeling and optimization approach for heat sinks. The optimized heat sink designs exhibit improved cooling performance and reduced pressure drop compared to traditional heat sink designs. This study also shows the importance of considering multiple design variables in the heat sink optimization process and extends immersion heat sink optimization beyond server-dependent solutions. The proposed approach can also be extended to other cooling techniques and applications, where optimizing the design variables of heat sinks can improve cooling performance and reduce energy consumption.
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Transient topology optimization for efficient design of actively cooled microvascular materials
Abstract Microvascular materials containing internal microchannels are able to achieve multi-functionality by flowing different fluids through vasculature. Active cooling is one application to protect structural components and devices from thermal overload, which is critical to modern technology including electric vehicle battery packaging and solar panels on space probes. Creating thermally efficient vascular network designs requires state-of-the-art computational tools. Prior optimization schemes have only considered steady-state cooling, rendering a knowledge gap for time-varying heat transfer behavior. In this study, a transient topology optimization framework is presented to maximize the active-cooling performance and mitigate computational cost. Here, we optimize the channel layout so that coolant flowing within the vascular network can remove heat quickly and also provide a lower steady-state temperature. An objective function for this new transient formulation is proposed that minimizes the area beneath the average temperature versus time curve to simultaneously reduce the temperature and cooling time. The thermal response of the system is obtained through a transient Geometric Reduced Order Finite Element Model (GRO-FEM). The model is verified via a conjugate heat transfer simulation in commercial software and validated by an active-cooling experiment conducted on a 3D-printed microvascular metal. A transient sensitivity analysis is derived to provide the optimizer with analytical gradients of the objective function for further computational efficiency. Example problems are solved demonstrating the method’s ability to enhance cooling performance along with a comparison of transient versus steady-state optimization results. In this comparison, both the steady-state and transient frameworks delivered different designs with similar performance characteristics for the problems considered in this study. This latest computational framework provides a new thermal regulation toolbox for microvascular material designers.
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- Award ID(s):
- 2143422
- PAR ID:
- 10496848
- Publisher / Repository:
- Springer Science + Business Media
- Date Published:
- Journal Name:
- Structural and Multidisciplinary Optimization
- Volume:
- 67
- Issue:
- 4
- ISSN:
- 1615-147X
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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