The paper presents both three and two-dimensional numerical analysis of convective heat transfer in microchannels. The three-dimensional geometry of the microchannel heat sink followed the details of the experimental facility used during a previous research step. The heat sink consisted of a very high aspect ratio rectangular microchannel. Two channel spacings, namely 1 mm and 0.3 mm (0.1 mm), were used for three-dimensional (two-dimensional) numerical model, respectively. Water was employed as the cooling liquid. The Reynolds number ranged from 200 to 3000. In the paper, thermal entrance effects and conduction/convection coupling effects are considered both for the test case of uniform channel inlet conditions and the complete geometry of the experiment. Finally, the comparison between measured and computed heat flux and temperature fields is presented. Contrary to the experimental work, the numerical analysis did not reveal any significant scale effect on heat transfer in microchannel heat sink down to the smallest size considered (0.1 mm).

Three different approaches were used in the present study to predict the influence of roughness on laminar flow in microchannels. Experimental investigations were conducted with rough microchannels 100 to 300μm in height (H). The pressure drop was measured in test-sections prepared with well-controlled wall roughness (periodically distributed blocks, relative roughness k* =k/0.5H≈0.15) and in test-sections with randomly distributed particles anchored on the channel walls (k* ≈0.04–0.13). Three-dimensional numerical simulations were conducted with the same geometry as in the test-section with periodical roughness (wavelength L). A one-dimensional model (RLM model) was also developed on the basis of a discrete-element approach and the volume-averaging technique. The numerical simulations, the rough layer model and the experiments agree to show that the Poiseuille number Po increases with the relative roughness and is independent of Re in the laminar regime (Re<2000). The increase in Po observed during the experiments is predicted well both by the three-dimensional simulations and the rough layer model. The RLM model shows that the roughness effect may be interpreted by using an effective roughness height keff. keff/k depends on two dimensionless local parameters: the porosity at the bottom wall; and the roughness height normalized with the distance between the rough elements. The RLM model shows that keff/k is independent of the relative roughness k* at given k/L and may be simply approximated by the law: keff/k = 1 − (c(ϵ)/2π)(L/k) for keff/k>0.2, where c decreases with the porosity ϵ.