2 First Steps - Conjugate Heat Transfer This Furst Steps - Conjugate Heat Transfer tutorial covers the basic steps to set up a flow analysis problem including heat conduction in solids. This example is particularly pertinent to users interested in analyzing flow and heat conduction within electronics packages although the basic principles are applicable to all thermal problems. Itis agsumed that youhave already completed the First Steps - Ball Valve Design tutorial since it teaches the basic principles of using Flow Simnlaion in greeter detail Open the SolidWorks Model 41 Copy the First Steps - Eleetonies Cooling flder into your waking diectay and ensure that the files are not read-only since Flow Simulation will save input data to these files. Click File Open. For cur work we set non-graduated white backeround Click Tools, Options. In the Options tree, select Display item. Thea in the Visualization tab, select white backstound colorand clear Graduated color background option. In the Open dislog box, browse 10 the Enclosure Assenbly.S10asu assembly located in the First Steps -Hleetronies Cooling folder and click Open (ar double-click the assembly). Altematively, you can drag and drop the Enclosure Assembly. SLAs" file to.an empty area of SolidWorks window.(Chapter 2 Hust Steps - Conjugate Heat transter Preparingthe Model Inatypicalassembly theremay bemany features, parts or sub-assemblies that are not necessary for the analysis Prior to creating a Flow Simulation project, tis a good practice tocheck themodel to find components that can be removed from the analysis. Excluding these components reduces the computer resources and calculation time required forthe analysis. ‘The assembly consists of the following components :enclosure, mothezboard and two smaller PCBs, capacitors, power supply, heat sink, chips, fan, screws, fan housing, and lids. You can highlightthese components by clicking on the them in the FeatureManager design wee. In this tutorial we will simulate the fan by specifying a Fam boundary condition on the inner face of theinlet lid. The fan has a very complex geometry that may cause delays while rebuilding the model, Since itis outside the enclosure, we can exclude ‘by suppressing &. 1 Inthe FeanmeManager design tee, select )1@ exalcipat L the Fan-12,andaallSerews components 7 Qomicwe--[B OA GE SB (esekcimorethanne component hola Seo @ down the Gtr! key while you select). =; any ot 29 mmm [PR bomen 2 Right-click any of the selected ’ = components and elect Suppress 4‘Suppresting tan and its cerews leaves open five holes in the enclose, We sregeing to perform an internal analysis, eo all holes mustbe closed with lids. To save your time, we created the lids and included them to the model. You just need to ‘unsupress them... ‘3. Inthe FeatureManagerdesign tree, sewenpers select the Inlet Lid, Outlet Lid and ros OS Screwhele Lid components and ey pattems DerivedL Patter 1 and = Local Pater! (these patterns contain cloned copies of the outlet and serewhole bids). belie Gwoonrts 4 Right-clickeny of theselected cmarettior + Somsponsats and lest 1B cotarehaus unsupprass 12 ‘Now you can start with Flow Simlation Create a Flow Simulation Project 4 Click Flow Simulation, Project, Wizard. 2 Onceinside the Wheard, select Create 1 inorder to create anew configuration and. nameit Inet Fan. Click Next, ‘Now we will create a new system of units named USA Electronics that is better suited for our analysis. 3 Inthe Unit system list select the USA system of units. Select Create new to add a new system of units to the Engineering Database and name it UER Electronica. {© Flow Simulation allows you to work with several pre-defined unit systems but often itis moreconvenient 10 define your own How Simulatonz01¥ lutorial aChapter? Fiat Steps - Conjugate Haat Trsaater ‘custom wit system. Bath predefined and custom unit systems are stored in the Engineering Database Tou aan arsate the desired system of units in the Enginesring Database or inthe Wizard {ba By scrolling through the different groups in the Parameter tree you can see the units Selected for all the parameters. Alshough most of the parameters have convention! units such as fs for velocity and CFM (eulbic fant per minute) for volume flow rate we will change a couple units that are more convenient for this model Since the physical sire caf the mad i velartvely smallit is mars camvenient to choose inches instead affest at the length unit. 4 Forthe Length entry, double-click its cell inthe Units column and selectInch, 5 Next expand the Hast sroup in the Parameter tee. ‘Since we are dealing witheleconic. ‘components itis mom comenient to ‘specify Total heat flow and power and ‘Heat flux in Watt and Watt? respectively ‘Click Next. 6 Sct the malysis type to intemal. Under Physieal Features selecttne Heat ‘conduction in solids check box. (Ld Heat conduction in solids was selected ‘because heat x genzrated by several ‘electronics components andwe are imerested to see how the heatis dissipated Proughthehest eink and athey colidparts enud then out # the fia (Click Next.Click Next. @ Expandihe Alloys folder andclick Steel ‘Stainless: 224 to assign it az 8 Default solid Lal in he Wiaralyou specify the defrult sali ‘material applied to ai sotid components in the Flow Simulation project. To specify ‘a different solid materia for one or mare components, you eam define a Salil (Material conzition for these components after the project iscreated Click Next. Select Heattransfer coefficient a: Defaultouterwall the mal condition and specify the Heat transfer coefficient value ot 5.5 ¥/="2/E and External fluid temperature of 50°F. The entered value of heat transfer codtticient is automatically covertedto the selected system of units (LSA Electronics) 2 Inthe Wall Conditons dialog box of the cent Wizard you specify the default conditions eI af the model walls. When Heat conduction in solids is abled. the Default outer wall thermal condition parameter aliows you to simslate heat exchange between the cuter model walls and surrounding emvtranmant. fn aur caze the baw is lscated in am air-conditioned room ‘with the air temperature of SO°F and heat transfer through the outer walis oy the enclosure due to the conection in the room can significantly contribute to the enclosure cooling. Cliske Next. ‘Although the initial temperature is more impartant for transient calculations tosee how muchtime it takesto reach a.cemain temperature, im astendy-ctmte analysis itis ueetul Flow Simulation 2010 Tutorial 25Chapter 2. First Steps -Conjugate Hest Transfer to set the initial temperature close 1o the anticipated final solution to speed up convergence, Inthis case we will setthe initial air temperature and the initial temperatux of the stainless steel (whichrepresents the material of enclosure) to 50°F because the box is located in an air-conditioned roam. 410 Setthe initial fluid Temperature and the Initial solid temperature t9 50°. ca connate onan a | a Minimum wall thickness. i Farteereee ———a4 sir na uc — ‘coanay ment thickness using information about the ——s Svaniaas —— ‘compurorional domain, anc fase on winch ae CRI ee jn you specify conditions axd goals. Prior to starting the calculation, we recommend that you check the minimum gap size and reinimuon wall thielovess to ensure that small features will be recognized. We will review these again afier all the necessary conditions and goals will be specified. Click Finish. Now Flow Simulation creates anew configuration with the Flow ‘Simulation data attached. ‘el Fre will use the Flow Simulation Analysis tree to define our analysis, just ar the Fanture Manager design ire is used to design your models. Right-click the Computational Domain icon and select Q twxcouta Hide to hide the wireframe box. a Bs ot ral GLA Fanis ape of flow bouday condition You can specify Fans at selected solid surfaces, free of Boundary Conditions and Sourees. 41 made! openings elo sed by lids you cam specify inlet or Outlet Fans. Yowoam also specify finson any faces within the Define the Fanflow region as imemal Fans. 4 Fan is considered as am ideal device eveating a flow with a certainvolume (or mass) flow rate, which depends om the difference berwesn the inlet and outlet pressures on the selected faces. If you analyze a model with a fan, you sholud know the fan's characteristics. Inthis example weuse one of the pre-detinedtans available in the Engineering Database. It you campot find an appropriate fm in the Engineering Database, youcan create your ownfm in ‘accordance with the fan's specification, 41 Click FlowSimulation, Insert, Fan. The Fan dialog box appears. 2 Sclectdhe inner face ofthe Inlet [9p2iSNAT z Lid par as shown. (To access | 4 a oe Y Y Inlet Lid in the graphics area | [erren and choose Select Other ov? jaccsaudaalolhelw a the poimer over tems in te ist feenaamatetintenassd of features until tie inner acois |W Pwhlated, the clic te Left ‘mouse button). 2. Select External inlet Fan as fan Type, 4) Inthe Fan listselectthe Papst 412 item under Pre-Defined, Axial, Papst. 5. Under Thermodynamic Parameters check that the Ambient Pressure Phy is the atmospheric pressure 6 Accept Face Coordinate System as the reference Coordinate System J. ow Sirmulation 2010 Tutosist aChapter 2 Fiest Steps - Conjugate Heat Transfer ‘ka Faor coordinate system is created automatically in the center of'a planar face when you select this face as the face to apply the boundary condition or jim. The Xaxis of this coordinate system is normal to the face The Face coordinate systemis crested when only one planar face is selected. ‘T Accept as the Reference axis. 1 arcades Faw & ClickoK @ | The new Fans folderandthe External - Be Seems Ft Inlet Fan 1 item appear in the Flow Simulation Analysis “ ree. {5 Now you cam ait he External Indet Fant item or ad 2224 10% 9 cu using Flow Simulation Analysis ree. This folder remains visible ea tontil tne last eure ofthis ppe is deleted’ You ea alsa mate a ea esture® folder to be initially available inthe ree. Right-cisc the alanis roject mame item and select Customize Trea t2 adder remove," ™ SSS folders. nec — (kel Sinaz the outler tie of the enciosure are at ambient atmospheric pressure, the presswe rise produced by the jan is equal to the presswe drop through the electronics enclosure Define the Boundary Conditions ‘A boundary condition is requized at any place whore thud enters.or exits the model, excluding openings where fanis specified. A boundary condition can be set in formof Pressure, Mass Flow, Volume Flow or Velocity. Youcan also use the Boundary ‘Condition dialog for specifying an Ideal Wall conditionthat isan adiabatic, frictionless wall or a Real Wall conditiontose the wall roughness and/or temperanre and/or hest ‘conduction coefficient at the model surfaces. Forinternsl analyses with Heatcond uction in solids crabled, youcan also set thermal wall condition onouter mode! walls by specityingan Unter Wall condition. 4 Inthe Flow Simulation analysis tree, rightclick the cerptnns oe Boundary Conditions icon and select Insert Seale Boundary Condition.2 Select the inner daces of al ult lidsas shown. @ tevcoecumunt 2. SelectPrascure Opening |@3) and Environment Pressure 4 chick OK “The new Environment Pressure 4 item appess in theFlow Simulation Analysis tee. [Di The Emironmant pressure consition is interpreted asa statie pressure for outgoing flows and as a total pressure ‘Yor incoming flows. Define the Heat Source 1 Click FlowSimulation, Insert, Volume Source. 2 Sekt main Cp fom de Epon flyouFearmeManagerdesim yg bombers» tree ireeas the component to p Brea. apply the valume source. A Sgro > 3 BD Commntacds ER comecs ee BD Powe Sucthew o $B eacetc > Poa A K PD made > 2 seater 2. Sclatite Hest Ganerson patel as Pommeter 4 Enters Wi inthe HeatGeneration Rate Q tox. 5 ClickoK 6 Inthe Flow Simulation Analysis wee click-pauce-click the 8} ses Sonn new VS Heat Generation Rate 1 item and rename it 0 Sy Planted main cnsp. Flow Simulation2010 Tutorial 20‘Chapter 2 First Steps -Conjupate Heat Transfer ‘bl Fo lume Haat Sources allow you to sparify the hear generation rate (in Watts) or the ‘volumetris haat generation rare (in Watts per volume) or a constaut emperanure boundiay condition forthe volume. it isalso possible to specify Surface Heat Sources ‘in terms of heat transferrate (in Watts) or heat flux (in Watts per area). (Click anywhere inthe graphic area to clear the selection. 1 Inthe Flow Simulation analysis tree, rightclick the Heat Sources icon and select Insert Volume Source. 2 1, oer SQ bceeseen ” Beet , ap reno 3 bras euer 100 inthe Temperature, re] arg bo , x Marcrets (| 4-9 raraieehco 0 4 cickok ? 5) PB kenseisi o Recin S Clickpase-click the new VS Temperature 1 itemand rename 1 [ill [leper itto Capacitors, Click anywhere inthe graphic areato clear the selection.© Following the same procedure as e above, setthe following volume os heat sources: all chipson PCBs : (Small Chip) with the total heat $B Fovers premtonmizof +, pee Power Supply with “s the temperature ot 120 os Mercols ff 4 8 a = eB tadertiaets » 1. sgn - WWerccareci> PS eectens Bresso > SD Copsctoc> » 2 Ferme |] +S cen Aeecresoin [3] ———si and ese PCB companens. 3 2 Inthe Solid ist expanaUser PR consvass Defined and selcct Tutorial pene Ree. SB Pee See SPiessna Ab imc SSpomce > oe smton » 4 cickox # fear) 9 Following the same procedure, specify solidmaterialsfor other components: + forthe main chip and allsmall chips assign the new Tutorial component package smuterial (available under User Defined); + thehest sink is made of Aluminum (available under Pre-Defined, Metals): + thelids (Inlet Lid, Outlet Lid, Screwhole Lid and al lids in both the DerivedLPatternl and Local Pattern] pattems) are made of the Insulator ‘material (available unser Pre-Defined, Glasses and Minerals). ‘Toselect apart, click itin the FeatureManager design tree or Solid Werks graphice 6 Chmgethenamect eachassioned solid material ‘The new, descriptive names should be: Pow - Tuteriet PoE, Chie - Tutectel conponeat package, Het Sink - Alusims, bide - Ineulaten Fob TaueP Choy Tawislereot cadens Ciick File, Save.Define the Engineering Goals. Specifying Volume Goals 41 Rightlice the Goals icon and select Insert Volume: Goals. 2 Intheftyout FestureManagerdesion |559/ | 3. Inthe Parametertable select the r Max check bax in the Temperature jaa ‘of Solid row. 4 Accept selected Use for Conv. (Use for Convergence Control) chesl: box touse this goal for convergence comzal., PeePPPeaPeePxA 5 Click OK The new VG Max Temperature of Solid 4 item ‘appears in the Flow Simulation Analysis tree, sense 6 Change the name of thenew item to YG Sell Chips Mex Tespereture. You sanalso change the name of the itemusing the (Feature Properties cialog that appear: if you rightclick the item and select Properties, ‘Click anywhere inthe graphic areato clear the selection. 7 Rightclick the Goals icon and select Insert Volume Goals.8 Select the Main Chip item in the ie AgouFenaeNaragerdesimtree, ee, 9 Inthe Parameter table select the rE oye ‘Max check box in the Temperature of Solid mow. 10 Click oK 11 Rename the new VG Max Temperature of Solid 1 item to VG Chip Max Texpereture, Click anywhere inthe graphicarea toclear theselection. peut» vb iioneus » 210 xaos! HE beste PR Hommes o Specifying Surface Goals 1 Right-click the Goals icon and select Insert Surface Goals.Chapter 2. First Steps - Conjugate Heat Transfer 2. Click the Flow Simulation Analysis Tree tab and click the External Inlet Far] item to ot co select the face where the goal is going tobe G ret tomy applied. 2 Inthe Parameter table selectthe Av check box in the Static Pressure mow. 4 Accept selected Use for Ganv. (Use for Convergence Control) check box touse this goal for convergence control. {Ga For the X/% Z) - Component of Force and 17 Z)~ Component of Torque surface goals you can select the Coordinate systemin which these wp yg goals will be cateulared, 5S Under Name Template, located at the bottom ‘Rare Temelite of the FropertyManager, cick inlet [P and tienzemove —_[SGiretFaariol the | and [Parameter 8 then remove the « field from the Name Template. ‘name Templts (lel 2 click oK F-test: Outlet Mass Flow Rate goat appexs. Specifying Global Goals 4. Right-click the Goals icon and selectinsert Global Goals. 9 # Gea cin metl| brat Stes bases Re Peano tema &Chapter 2. First Stipe -Conjugate Mast Transfer Temperature of Fluid rows and accept elected Use for Conv. (Use for Convergence Control) check boxto use there goals tor comerzence contral. OW OK CLO OK OKOKER CL OMOK erro feo]fees] 3) Remove the ctunber> field trom the ® i Name Template and click OK GU Av BR ict Yerganinnect ad Sta Presure and GU Av Temperate of RI Fisid goals appear. Ya 16 Croc Tomerse Mp oc onal cige tng Inthis tutorial the engineering goals are set to determine the maximumtemperature of the beat generating components, the temperature rise inair and the wressure drop and mass flow rte through the enclosure. Click Fite, Save. Neatletus check the automatically detined geomenry solution seitings for this project.Changing the Geometry Resolution 41 Click Flow Simulation, Initial Mesh. 2. Select the Manual specification ofthe ‘minimum gap size check box. —_a 3 Ener 0.2 in forthe Minimum gap size (ie passage os bbetvveen the fins of the heat sink). {LE mering values for the minimum gap size and mininurm ‘wall thickness is important when you have small feonures, Setting these values accurately ensures that ‘the small faatures are not “passed over” by the mesh ‘The munéomm wall thisiness chould! be spanifizd omly if there ars fluid aells om either side of a small solid faature Incase of internal analyses, there are no fluid cells in the ‘ambient space outside of the enclosure. Thevefore beumdaries berwcen internal flow and ambient space are always resolved property. That is why you should not take into ‘secount the walls of the steel eabiner. Bott the minimum gap size oid the minimum wall thickness are tools chat help you to create @ model-adaptive mesh resulting in increased aeeurazy: Flowaver the minimum gap size cetting irthe mare powapul ons. The fact is that she Flow Simalation mesh is constructed so that the specified Level of {tial mash commrals the minimum number afmach cells par minimum gap size. nd this muonber is equal to or greater than the number of mesh calls generated per minimum wall thickness. That's why evan ifyou have a thin colid feature incide the flow region itis notnecessary to specify minimum wall thickness if is greater than or ‘equal to the minimum gap size Specifying the minimum wall thickness is necessary if ‘you want to recalve thin walls smaller than the smallest gap. Click on.Chapie 2 First Steps~Gonjugate Heat Transfer Solution 1) Click Flow Simulation, Solve, Run. 2 Chick Run. ‘Thesolver takes about twenty to thisty minutes to nm ona typical PC. ‘bal eu may notice that different goats take different number of iterations to converge The goal-oriented philosophy of Flow Simulation allows you to get the anmers you need in the shartest amowst of time. For example ifyou were only interested in the temperature of fluid in the exclaswre, Flow Simulation would have provided the result more quickly then ifthe solver was allowed ta fully converge on all of the parameters. View ing the Goals 1 Right-click the Goalsicon under Results and select Insert.) B§ reams AE Mess 2 caus © Prieta © satverbet 2 Click Add Allin the Goals dialog. 3 Click OK.Am Excel spreadsheet with the goal results will open. The fizst sheet will show a table ‘You cam see that the maximum temperature in the-main chip is about 88 "F, and the maximum temperature over the small chips is about 91 *F. Goal progress bar is a qualitative and quantitative characteristic of the goal convergence process. When Flow Simulation analjzes the goal convergence, it calculates the goa! dispersion defined as the difference between the maximum and minimum goal values over the analysis interval reckoned from the last iteration and compares this dispersion with the zoal's convergence eriterion dispersion, dither specified by you or automatically determined by Flow Simulation as a fraction of the goal’s physical parameter dispersion aver the computational domain The percentage ‘of the goal’s convergence criterion alspersian ta the goal's real dispersion over the analysis intenatis shawn in the goal's convergence progress bar (when the goat's real sispersion becomes equal ov smaller than the goal's convergence criterion dispersion, ‘the progress bar is replaced by word "Achieved" ). Natwratty, iY the goat's reat dispersion oscillates, the progress bar ascillates alsa, maraover, when a hard problem is solved it com noticeably regress, in particular from the “achieved” level. The calculation cam finish ifthe iterations (in travels) requiredfor finishing the calculation have been performed, or ifthe goal convergence criteria are satisfied before performing the required member of iterations. You can specify other finishing conditions at your discretion. To analyze the results in more detail let us use the various Flow Simulation results processing tools, The: best method for the visualization of how the fluid tlowsinside the enclosure istocreate flow trajectories.Ghepter2 First Stps- Conjugate Heat Transfer Flow Trajectories 41 Right-click the Flow Trajectories icon and selec imee (ow Fate os 2. Click the Flow Simulation Analysis Tee tab and then click the External Inlet Fan] item to select ‘the inner face of the Inlet Lid. 3 Serme Numberet Taectoses GA 1 200 4. Keep Reference inthe Start Pein up i pfReference is selected then the majectory start points are taken from the specified face ar 2 —_ 5 Under Options sei Draw Trajectories As 3g 19 Bands. 6 Click View Settings. 7. Inthe View Settingsdislogbox, change the Parameter from Pressure to Velocity. 8 Goto the Flow Trajectories tab and notice that the Use from contours option is selected,Li This setting defines how trajectories are colored. IfUse from contours is selected then the trajectories are colored with the distribution of the parameter specified on the Contours tab (Velocity in our ease). If you select Use fixed color then ail flow trajectories have the same color that you Specify on the Settings tab of the Flow Trajectories dialog bax. 9 Click OK wo save the changes and exit the View Settings dialog box. 410 In the Flow Trajectoriagdislogclick OK ‘The new Flow Trajectories 1 item appearsin theFlow Simulation Analysis mee. ‘This is the picture you should see. Notice that there areomly a few trajectories along the adjacenttothe wall PUB2> and this may cause problems ‘with cool ing of the chips placed on this PCB. Additionally the blue color indicates low velocity in front of this PUB Right-click the Flow Trajectories 4 item. and selectHide. Click anywhere-inthe graphic area to clear the 5 eV Flot Pet uame Cina oer suricePxs Smale Let us examine the velocity distribution in more oer ‘come derail, Me Goat: pes) FRe Goat: Pl PingsChapter 2 First Steps Conjugate Heat Transfer Cut Plots 1 5. Setthe Number of colors to about 30. 6 Click OK Right-click che Cut Plots icon and celect Insert. oe & vera ‘Keep the Front plane asthe section plane. Click View Settings. (Change the Min and Max values to and 10 spectively. The specitied integer values produce apaletie where itis more easy todetemmine the value, Inthe CutPlot dialog box click OK “The new Cut Plot 1 item appears in the Flow Simulation Analysis wee, seteerne Top view EDIE ED ontne Standard Views tite.Letus now look at the fluid temperature, 9 Double-click the palette bar in the upper left comer ot the graphics area. The ‘View Settings dialog appears. 10 Change the Parameter tram Velocity to Fluid Temperature 11 Change the Min and Max values to $0 and zo respectively. 42 Click the Vectorstab and change the Arrow size to 0.2 by typing the valuen the ‘box under the slider Lil Natice that you cam speaiy a value shat is outside of the slider’s range 18 SettheMax valucto 2 rt/s Flow Situlation2010 Tutorial 225Chapt? Fist Shs -Conjugite Heat Teansfer Lal By specifying the eustom Min and Max values you can control the vector length. The vectors whas e velocity exceeds the specified Max value will have che same length as the vectors whase velocity i equal e Max. Likewise, the vectors whose velocity is less than the specified Min value will have the same length as the vectors whose velocity is equal to Min. We haveset | jos to dlplay areas oflowvelocign 14 Click OK. 15 Rightclick the Cut Plot 1 iuem and select Edit Definition 46 ClickVectors ("2 17 Changethe Offset ff 10-0.30 in. 48 Expundithe Veetors group bor. Using the siderset te Vector Spacing 2! to ~0.18 in. 49 Cuick oKRight-click the Cut Plot 1 item and select Hide, Letus now display solid temperature. Surface Plots 41 Right-click the Surface Plots item and selec Insert. nn] & tence i 5 Fw cine |Chapter 2. Ficst Steps - Conjugate Heat Transfer 2. Inthe flyout FestureManager design te click the Main gaggia (Chip, HeatSink and all Small Chip componertsta select their surfaces. 3. Click View Settings. 4. Inthe View Settings dialog box, change the Parameter to Solid Temperature. SS Change the Min and Max values to 50 and 1220 respectively. 6 Click OK. 7. Inthe Surface Plot dialog box click OK S . The creation of the surtace plot may take some time because many faces need to be eclored, ® Repeat steps 1 and 2 and select the Power Supply and all Capacitors components, then click oK 9 Onthe View toolbar click Wireframe (6) to show the face outlines.‘Youcan viewand anslyze the msults further with the post-processing tools that were ‘shown in the First Steps - Ball Valve Design tutorial. Flow Simulation allows you to quickly snd easily investigate your design both quantitatively and. qualitatively. (Quantitative results such as the maximum temperature in the component, pressure drop ‘through the cabinet, and air temperature rise will allow you to determine whether the design is acceptable or not, By viewing qualitmive results such as air flow patterns, and ‘heat conduction patterns in the solid, Flow Simulation gives youthe necessary insi ght 10 Jocate problem areas or wealmesses in your design and provides guidance onhow ta ‘improve or optimize the design