Experimental validation of additively manufactured optimized shapes for passive cooling

Lazarov, Boyan Stefanov; Sigmund, Ole; Meyer, Knud Erik; Alexandersen, Joe

doi:10.1016/j.apenergy.2018.05.106

Cited by 88 publications

(32 citation statements)

References 37 publications

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“…Ramalingom et al [130] proposed a sigmoid interpolation function for mixed convection problems. Lazarov et al [154] performed an experimental validation of the optimised designs from Alexandersen et al [153] using additive manufacturing in aluminium, showing good agreement with numerical results and highlighting the superiority of topology-optimised designs. Lei et al [155] continued this work and used investment casting to experimentally investigate a larger array of heat sink designs comparing them to optimised pin fin designs.…”

Section: Natural Convectionmentioning

confidence: 87%

“…For species transport, there are four papers [93,98,105,107]. For conjugate heat transfer, there are eight in forced convection [110,117,119,122,126,129,132,135] and six in natural convection [150,151,[153][154][155]160]. The fluid-structure interaction category counts four papers [164,168,172,173], but it must be noted that, common for all, the three-dimensional design freedom is severely limited, as the design domain is restricted in the third dimension.…”

Section: Three-dimensional Problemsmentioning

confidence: 99%

“…Only 12 papers, or 7%, contain some form of experimental investigation of the topology-optimised designs. These cover fixed-geometry fluid diodes [43,68], small scale rotary pumps [62], forced convection heat sinks [116,128,141,146], passive coolers for light-emitting diode lamps [154,155], porous bioreactors [186], particle separators [102], and conformal cooling channels [142].…”

Section: Experimental Validationmentioning

confidence: 99%

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A Review of Topology Optimisation for Fluid-Based Problems

Alexandersen

Andreasen

2020

Fluids

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203

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This review paper provides an overview of the literature for topology optimisation of fluid-based problems, starting with the seminal works on the subject and ending with a snapshot of the state of the art of this rapidly developing field. “Fluid-based problems” are defined as problems where at least one governing equation for fluid flow is solved and the fluid–solid interface is optimised. In addition to fluid flow, any number of additional physics can be solved, such as species transport, heat transfer and mechanics. The review covers 186 papers from 2003 up to and including January 2020, which are sorted into five main groups: pure fluid flow; species transport; conjugate heat transfer; fluid–structure interaction; microstructure and porous media. Each paper is very briefly introduced in chronological order of publication. A quantititive analysis is presented with statistics covering the development of the field and presenting the distribution over subgroups. Recommendations for focus areas of future research are made based on the extensive literature review, the quantitative analysis, as well as the authors’ personal experience and opinions. Since the vast majority of papers treat steady-state laminar pure fluid flow, with no recent major advancements, it is recommended that future research focuses on more complex problems, e.g., transient and turbulent flow.

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Section: Natural Convectionmentioning

confidence: 87%

Section: Three-dimensional Problemsmentioning

confidence: 99%

Section: Experimental Validationmentioning

confidence: 99%

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A Review of Topology Optimisation for Fluid-Based Problems

Alexandersen

Andreasen

2020

Fluids

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203

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“…Because they are not bound to a geometric family, the way truss or surface-based lattices can be, TO geometries are less constrained: assuming an infinitely small mesh size, the globally optimal geometry for a given problem will be one of the considered solutions. Even if mechanical optimization comes quicker to mind when talking about TO, many thermal TO investigations have been carried out to identify optimal designs of 2D extruded [31,32] and 3D [33,34] heat sinks. However, TO still suffers from slow industrialization, because of its significant computation times, its complexity of use requiring a rare expertise, and its expensive software and hardware requirements [35].…”

Section: Related Workmentioning

confidence: 99%

Parametric design of graded truss lattice structures for enhanced thermal dissipation

Vaissier

Pernot

Chougrani³

et al. 2019

Computer-Aided Design

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Truss lattice structures are intricate geometries, whose fabrication has recently been simplified by the development of Additive Manufacturing (AM) technologies. These lightweight geometries present great volume densities and surface-to-occupancy ratios, which makes them ideal for thermal dissipation applications. This paper introduces a new framework for the parametric design of graded truss lattice structures that maximize passive cooling. It exploits the results of a semi-analytic formulation and analysis of the volume density and surface-to-occupancy ratio of state-of-the-art unit cells. In particular, it comes out that any truss lattice structure presents an optimal beam diameter over unit cell size ratio that maximizes its surface-to-occupancy value. This value and the ratio for which it is reached are identified and compared for the most common unit cells. The unit cell with the maximal surface-to-occupancy ratio is then identified, along with its set of optimal parameters, taking into account additive manufacturing constraints. The validation of this optimal geometry is performed by populating pre-defined design spaces of both academic and industrial case studies. An orientation strategy and a parametric gradation approach are also proposed to further optimize the generated heat sinks and maximize passive cooling. These results are very helpful to support decision making during the parametric design of a heat sink and to identify, a priori, the optimal unit cell, its control parameters, its orientation and its gradation strategy. The generated geometries are compared with traditional heat sink structures through static heat dissipation simulations, in order to demonstrate their interest.

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“…In the context of topology optimization based on the level-set method [46], Coffin & Maute [16] consider both steady-state and transient natural convection problems. The experimental validation of topology optimized devices for conjugate heat transfer problems has been rarely performed, but there are a few contributions [20,30,32,34]. In particular, Lazarov et al [32] presents the experimental validation of the numerical results from Alexandersen et al [6] using additive manufacturing in aluminium, closing for the first time the design-validation-manufacturing cycle for topology optimization of heat sinks passively cooled by natural convection.…”

Section: Introductionmentioning

confidence: 99%

A “poor man’s” approach for high-resolution three-dimensional topology design for natural convection problems

Pollini

Sigmund

Andreasen

et al. 2020

Advances in Engineering Software

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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.

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Experimental validation of additively manufactured optimized shapes for passive cooling

Cited by 88 publications

References 37 publications

A Review of Topology Optimisation for Fluid-Based Problems

A Review of Topology Optimisation for Fluid-Based Problems

Parametric design of graded truss lattice structures for enhanced thermal dissipation

A “poor man’s” approach for high-resolution three-dimensional topology design for natural convection problems

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