3D topology optimization design of air natural convection heat transfer fins

This study focuses on the fin-tube heat exchanger and utilizes topology optimization methods to design a completely new fin structure. In this optimization process, complete Navier-Stokes (N-S) equations were used to describe the steady-state incompressible flow, and the Boussinesq model was employed to simulate natural convection. The flow equations were coupled with the heat convection–diffusion equation to achieve topology optimization for natural convection heat transfer. Topology optimization was conducted using density-based optimization methods, and interpolation was performed on the permeability and conductivity of the distributed materials. Given the initial fin structure, an interpolation progressive approach was adopted to obtain a new “ airfoil-shaped” optimized structure through density-based topology optimization method for natural convection. The new structure enhances the convective heat transfer by perforating the fins. The perforations are mainly concentrated in the central region of the heat exchanger and the upper half of the fins. The new structure, compared to the prototype structure, not only has a reduced volume but also exhibits a decrease in convective thermal resistance within a larger range of heat flux densities, as revealed by CFD simulations. Moreover, as the heat flux density increases, the rate of reduction in convective thermal resistance shows an upward trend for the new structure compared to the prototype structure.