Design

g of heat sink ((1-3))

MEL 806
Thermal System Simulation (2-0-2)
Dr. Prabal Talukdar
Associate Professor
Department of Mechanical Engineering
IIT Delhi

Fins - Recapitulation
&
Q
conv = hA s (Ts T )

There are two ways to increase the rate of heat transfer

too increase
c e se thee convection
co vec o heat
e transfer
s e coefficient
coe c e h
to increase the surface area As
Increasing h may require the installation of a pump or fan,
Or replacing
p
g the existingg one with a larger
g one
The alternative is to increase the surface area by attaching to
the surface extended surfaces called fins
made of highly conductive materials such as aluminum

Finned-tube heat exchanger

Longitudinal Fins
Rectangular

Triangular

Trapezoidal

Concave parabolic

Convex parabolic

Radial Fins

Triangular profile
Rectangular profile

Hyperbolic profile

Radial fin coffee cup

Pin Fins

(a)Cylindrical (b)conical (c) concave parabolic (d) convex parabolic

Plate Fins
The thin p
plate fins of a car radiator g
greatly
y increase the
rate of heat transfer to the air

Fins from nature

Fin Equation
dT
Q& x = kA c
dx
d Q& x
&
&
Q x + dx = Q x +
dx
dx

&
dQ
conv = hdA s (T T )

Energy Balance:
&
dQ
x dx + hdA ( T T )
&
= Qx +
s

dx
dT
h dA s
(T T ) = 0

dx
k dx

Q& x = Q& x + dx + d Q& conv

d
A
dx

d 2T
dx

1 dA c dT 1 h dA s
(T T ) = 0
+

A c dx dx A c k dx

Fins with uniform cross sectional area

d 2T
dx

1 dA c dT 1 h dA s
(T T ) = 0

A c dx dx A c k dx

dA c
= 0
dx

A s = Px
d 2T
dx

dA s
= P
dx

hP
(T T ) = 0

kA
c

Excess temperature
( x ) T ( x ) T
d 2
dx

m 2 = 0

(a) Rectangular Fin (b) Pin fin

General Solution and Boundary

Conditions
d 2
dx

m 2 = 0

m2 =

hP
kA c

( x ) T ( x ) T

The g
general solution is of the form
( x ) = C 1 e mx + C 2 e mx

Convection from tip

q denotes

BCs
T (0 ) = T
(0 ) = Tb T b

hA c [T ( L ) T ] = kA c

h ( L ) = k

cosh m ( L x ) + ( h / mk ) sinh m ( L x )
=
b
cosh mL + ( h / mk ) sinh mL

d
|x =L
dx

dT
|x = L
dx

&
Q

Heat Transfer from Fin Surface

d
& =Q
& = kA dT |
Q
=

kA
|x =0
f
b
c
x =0
c
dx
dx

& =
Q
f

hPkA c b

sinh mL + ( h / mk ) cosh mL
cosh mL + ( h / mk ) sinh mL

Another way of finding Q

Q fin = A fin h [ T ( x ) T ]dA fin = A fin h ( x ) dA fin

Insulated tip
General Sol: ( x ) = C 1 e mx + C 2 e mx
BC
C 1:

(0 ) = Tb T b

cosh m ( L x )

=
cosh mL
b
q f = q b = kA c

qf =

dT
d
| x = 0 = kA c
|x =0
dx
dx

hPkA c b tanh mL

BC 2:

d
|x = L = 0
d
dx

Prescribed temperature
This is a condition when the temperature
p
at the tip
p is known
(for example, measured by a sensor)

(
L b )sinh mx + sinh m ( L x )

=
sinh mL
b
qf =

cosh mL ( L b )
hPkA c b
sinh mL

Infinitely
y Long
g Fin ((Tfin tip
( L ) = T ( L ) T = 0

Boundary condition at the fin tip:

The general solution is of the form
( x ) = C 1 e mx + C 2 e mx

Possible when C1 0

( x ) = C 2 e mx
Apply boundary condition at base and find T
T ( x ) = T + ( T b T ) e

Q longfin = kA c

dT
|x =0 =
dx

hP
kA c

hPkA

( T b T )

as

= T)

Corrected fin length

g
Corrected fin length:
g

Lc = L +

Ac
P

Multiplying the relation above by

the perimeter gives
Acorrected = Afin (lateral) + Atip
t
Lc,rectangularfin = L +
2

L c,cylindrica lfin = L +

D
4

Corrected fin length

g Lc is defined such that heat transfer from a fin of
length Lc with insulated tip is equal to heat transfer from the actual
fin of length L with convection at the fin tip.

Fin Efficiency
y

fin =

Actual heat transfer rate from the fin

Q fin

= Ideal heat transfer rate from the fin

Q fin , max

if the entire fin were at base

temperature

In the limiting case of zero thermal resistance or

infinite thermal cond
conductivity
cti it (k ),
) the temperat
temperature
re
of the fin will be uniform at the base value of Tb.

Q fin = fin Q fin , max = fin hA fin (Tb T )

=
longfin
l fi

Q fin

Q fin , max

hPkA c (Tb T ) 1
=
hA fin (Tb T )
L

insulatedt ip =

Q fin

Q fin , max

kA c
1
=
hp
mL

hPkA
h
k c (Tb T ) ta
tanh m
mL tanh mL
=
hA fin (Tb T )
mL

Fin Effectiveness

fin =

Q fin

Q nofin

Q fin
hA b (Tb T )

longfin =

Q fin

Q nofin

Heat transfer rate from

the fin of base area Ab
Heat transfer rate from
the surface of area Ab

hPkA
h
kA c (Tb T )
=
hA b (Tb T )

kP
hA c

1. k should be as high as possible, (copper, aluminum, iron).

Aluminum is p
preferred: low cost and weight,
g , resistance to corrosion.
2. p/Ac should be as high as possible. (Thin plate fins and slender pin fins)
3. Most effective in applications where h is low. (Use of fins justified if when the
medium is gas and heat transfer is by natural convection).

Fin Effectiveness

Q fin

fin =

Q nofin

Q fin
hA b (Tb T )

Heat transfer rate from

th fifin off base
the
b
area Ab
Heat transfer rate from
the surface of area Ab

fin = 1

Does not affect the heat transfer at all.

fin < 1

Fin act as insulation (if low k material is used)

fin > 1

Enhancing heat transfer (use of fins justified if fin>2)

Overall Fin Effectiveness

When determining the rate of heat transfer
from a finned surface,, we must consider the
unfinned portion of the surface as well as the
fins. Therefore, the rate of heat transfer for a
surface containing n fins can be expressed as

Q total , fin = Q unfin + Q fin

= hA unfin ( Tb T ) + fin hA fin ( Tb T )
= h ( A unfin + fin A fin )( Tb T )

We can also define an overall

effectiveness for a finned surface as the
ratio of the total heat transfer from the
finned surface to the heat transfer from the
same surface if there were no fins

fin , overall =

Q total , fin

Q total , nofin

h ( Aunfin + fin A fin )( Tb T )

hA nofin (Tb T )

Efficiency of circular, rectangular, and triangular fins on a plain surface of

width w (from Gardner, Ref 6).

Efficiency
Effi
i
off
circular fins of
length L and
constant
thickness t (from
Gardner, Ref. 6).

Proper length of a fin

a has the same
meaning as m
a =

hP
kA c

Optimizations
p
Maximize heat transfer w
w.r.t.
rt
Fin thickness t
Profile length b
Heat transfer
f increases asymptotically with
increase in thickness
But
B t what
h t should
h ld b
be th
the optimum
ti
thi
thickness
k
if th
the
volume (= Ltb) of the fin is constant or the profile
area (= bt) is constant?

Constant Profile Area

Heat transfer from a fin with the adiabatic tip
q f = hPkA c b tanh mb

Assuming that L>>t and using P 2L,

2L
hP
b, we get:
Ac = Lt,
Lt Ap = bt and
d mbb =
t
kA c

h2L
q f = h2LkLt b tanh
b
kLt
Rearranging:
1/ 2
2h
1/ 2
1/ 2
q f = (2hk ) L b t tanh b
kt

Constant p
profile area
In terms of Ap (= bt)

P 2L, Ac = Lt

mb =

hP
kA c

b = b 2 h

k
kt

1
2

= A

b 2h

b k
bt
kt

1
2

2h
= Ap
3
kt

q f = (2hk)1/2 Lb t1/2 tanh mb

q f = (2hk )

1/ 2

q f = (2hk )1 / 2 L b

1
t2

L b

1
t2

1
2

2h

tanh A p
3
kt
1
2

2h

tanh A p
3
kt

1
2

Optimum
p
condition
q f = (2hk )

1
1
2 L b t 2

1
2

1
2

2h
tanh A p 3
k
kt

q f = ( 2hk ) Lb

1
t2

1/ 2

1/ 2

q f = (2hk )

L b t

tanh

dq f
=0
dt
1/ 2

3
2A

2h
6 = sinh 2 where = mb = t
p
k
= 1.4192 Gives optimum fin efficiency to be 0.627

1/ 2

2h
tanh
kt

Optimum
p
condition

Let us name profile fin length and fin thickness to be bo and to for the
optimum condition
Substituting Ap = boto in
1/ 2

2h
= mb =
k

1/2

2h
= mbo =
k

We get,

3
2A

3
2

t o bo t o

For constant profile area

Solving for to yields
optimum fin thickness
1/ 2

2h
to =
k

bo

Solving for bo yields the

optimum fin profile length
1/ 2

kt o
b o =

2h

Constant heat transfer from a fin

If the heat transfer rate is constant
1
2

q f = ( 2hk ) Lb

1
t2

1
2

2h
tanh A p 3 L
kt

tanh = tanh1.4192 = 0.8894

Solving for t gives the optimum fin thickness to for
constant heat transfer from a fin

qf

to =
(2hk)1/2 w

0.8894
L
b

22

00.632
0.632
0 632
632 qqff
ttoo ==
22
hkL
hkw bb

Because,

A p = b0 t 0

Optimum
p
value
1
2

2h
= mb0 =
bo
kt0

Si
Since,

Re-arranging,

1
2

k
b0 =
2h
1
2

k
b0 = 1.4192
2h

0.798 q f
b0 =
hL b

1
t o2

1
2 2

0.632 q
f

2
hkL b

0 632 q f
0.632
to =
2
hkL b

Constant fin volume or mass

The volume of the fin is V = Lbt
And profile area is Ap = bt = V/L
Since , the width L is not a parameter this problem is
basically the same as the constant profile area.

q f = (2hk )

1
2 L b

1
t2

1
2

V 2h
tanh 3
L kt
1
2

1
1

2 2
t0

2h
b 0 2h
= V
= mb 0 = b 0

b0 t 0L k
kt 0

Optimum
p
length
g and thickness
The optimum fin thickness with a constant
2
1
fin volume :
using

V 3 h 3
t0
L k
V
t0 =
b0L

Optimum
p
fin length
g

1
3

V k
b0

L h

Multiple
p Fin Array
yI
Free (Natural) Convection Cooling
For a single fin, the consideration is given to
the thickness and length of the fin to get the
maximum heat transfer rate.
Additional consideration for fin array: fin
spacing z and number of fins n for a given
plate area L x W
In general, the thickness of fin is usually much smaller than
the fin spacing z.

Small Spacing
p
g Channel
Consider a small hot p
parallel p
plate channel with constant
wall temperature To.
Cold air at T enters through the bottom of the channel
by natural convection.

Assumptions
p
Assume a fullyy developed
p flow.
Assume that length of the channel is long enough so that
the temperature of air at the outlet becomes To.
The number of fins n can be calculated by n = W
z+t
W
For the current analysis z>>t, Hence n
z

Momentum Equation
q
The heat transfer rate for the channel:

& p (To T )
q f = mc
& = vA
m
A cf
W
A cf = (zb) = Wb
z
For finding the average velocity, we need to solve the
momentum
t
equation
ti in
i y di
direction
ti
0

v
v
P
u
+v =
+ 2 v g
y
y
x
For a fully developed flow

Pressure Gradient
Since both ends of the channel are open,
p , the p
pressure
gradient is given by: P

= g

So, the momentum equation becomes:

2v
0 = ( g) + 2 g
y
( )g
2v
=
2

The Boussinesq approximation:

= (T T )

Thermal expansion coeff.

1
=

T P

Average
g velocity
y

Using Boussinesq approximation:

g(To T )
2v
=

y 2
Constant
Integrate twice with B.C. (i) no slip and (ii) symmetry at the centerline
2
g(To T ) x
v=
1

8
z / 2

Upon integrating this along the spacing z,

g velocity
y can be calculated:
the average

g(To T )z 2
v=
12
12

Mass Flow Rate

& = vA cf
m
A cf = Wb
g(To T )z 2
Average velocity v =
12
g((To T ))z 2
& =
Wb
Mass flow rate m
12

& p ((To T )
q f = mc
Heat transfer from
fin array with
small spacing

g(To T ) 2 z 2
q f ,small = c P Wb
12
q f ,small z 2

Large
g spacing
p
g channel
Consider a large spacing, a large enough for
each
hb
boundary
d
llayer tto b
be iisolated
l t db
between
t
isothermal plates
The
Th Nusselt
N
lt number
b ffor natural
t l convection
ti iin air
i
for a vertical plate
hL
Nu =
= 0.517 Ra 0L.25
K air

Wh
Where
the
th Rayleigh
R l i h number
b iis d
defined
fi d as
Ra L =

g ( T0 T ) L3

Heat Transfer Equation

q
In above equation RaL is the Rayleigh number
(f a fl
(for
flow over a plate
l t off length
l
th L) , is
i th
the
volumetric expansion coefficient, is the thermal
diffusivity and g is gravity
diffusivity,
gravity.
The volumetric expansion coefficient =1/Tf
Where Tf is the film temperature
Using Newtons law of cooling, the heat transfer
rate fins for the large channels can be written as
q f ,l arg e = A s h (T0 T )

Heat Transfer Equation

q
The heat transfer area As is obtained as
W
As = 2bLn = 2bL
z

Inserting equation n W in the heat transfer equation

z
yields
W
q f ,l arg e = 1.034 bk air Ra 0L.25 (T0 T )
z
Hence,

q f ,l arg e

Optimum
p
Fin Spacing
p
g
The optimal spacing can be obtained by
equations of heat transfers

q f ,small = q f ,l arg e
1
L3 4

g(T0 T )
2.3

z opt

1
2.3Ra
R L4

Forced Convection Cooling

g

Small spacing channel

Flow between parallel plates in the case of a small
spacing channel is known as Couett-Poiseulli flow.

Small spacing
p
g channel
The x-momentum
x momentum equation:
0

2u
u
u
P
2u
u
+v =
+ 2 + v 2
y
x
y
x
x
For a fully developed flow

Th
The pressure gradient
di t along
l
th
the channel
h
l iis
constant:
P P
x

Momentum equation
q
reduces to

2 u P
2 =
L
y

Velocity
y Expression
p
Integrating the above equation twice and using
the no slip and symmetry boundary condition,
the velocity u can be expressed as
2
Pz 2 (To T ) y
u=
1

8L
z / 2

The average velocity can be obtained

u =

1
A

udA

z2 P
u =
12 L

Heat Transfer from Fin

The heat transfer rate

& c p (T0 T )
q f ,small = m
z 2 p W

& =
m
12L zb z

q f ,small

z 2 p
= Wb
cp ( T0 T )
12L

q f ,small z

Large
g Spacing
p
g Channel
Assumption:
Consider
C
id a llarge spacing
i channel
h
l
Each boundary layer is isolated
The pressure drop is assumed to be constant
For laminar flow the Nusselt and Reynolds number
i written
is
itt as ffor Pr
P >0.5
05
hL
N L=
Nu
=
K air
Re L =

UL

1
0.664 Re
R L2

1
P 3
Pr

Heat Transfer Equation

q
Heat transfer equation

q f ,l arg e = A s h (T0 T )
1

q f ,l arg e
q f ,l arg e

k air
W
= 2 bL
0.664 Pr 3 Re 2 (T0 T )
z
L
W
= 1.33288 bbk air
z

3
Pr

1
UL 2

(T0 T )

Since P was assumed to be constant, U may

be expressed in terms of P and z
Considering the shear stress is the root cause of
the
h pressure d
drop, apply
l the
h fforce b
balance
l
((next
page)

Heat Transfer Equation

q
W
2 (bL ) = P(Wb )
z

The coefficient of friction for laminar flow

Cf =

1
U 2
2

1
= 1.328 Re L2

Eliminating the

Pz
U =
1 1

2 2
1.328L

Heat transfer equation

q

1
Pr PL 3

q f ,l arg e = 1.208Wbk air

2

q f ,l arg e

2
z3

2
z3

2
3

(T0 T )
q f ,small z 2

Optimum
p
spacing
p
g
The equation for optimized spacing
1
4

z opt

1
Pr PL 3

= 2.725
2
L
PL

q f ,small

z 2 p
c p ( T0 T )
= Wb
12L

q f ,l arg e = 1.208Wbk air

2

2
z3

(T0 T )

I
Inserting
ti above
b
equation
ti in
i th
the h
heatt ttransfer
f equation
ti
1
PL 2

q max
k
(T0 T )

= 0.619 air
2
WLb
L

The pressure drop may be estimated with an assumption

fL
1
Dh

z opt
L

fL U 2 U 2
P =

Dh 2
2

1
3.24 Re L2

1
Pr 4

Multiple
p Fin Array
y II
Heat transfer
from a single fin

q s,f = hPkA c b tanh(mb)

where, A p = bt, A c = Lt, P 2L and = mb
1/2

hp 2h
m=
=
kA c kt

q s,f = h(2L)k(Lt)b tanh

1/2

2hkA p
=

L b

q s,f

b tanh

Heat transfer from base wall

Consider heat transfer rate qw at the base
wall between two fins
q w = h w Lzb
W
W Ap
z=
t =

n
n
b
W Ap
qw
= h w b

L
b
n
Where, n is number of fins

Total heat transfer from fin

The total heat transfer rate from the multiple
p fin array
y is:
q w = h w Lzb

q s,f = h(2L)k(Lt)b tanh

1/2

2hkA p
=

L b

q s,f

b tanh

W
W Ap
z=
t =

n
n
b
W Ap
qw
= h w b

L
n
b

1/2

2hkA p
W Ap
q total
= n
b tanh + h w b
L
b
b
n

Expression
p
for single
g fin
To find the maximum total heat transfer with respect to b,
we set the derivative equal
q
to zero

dq total
=0
db

And finally obtained an expression:

2
2

2h w b
tanh 3 sec h =
k

If hw is ass
assumed
med to be zero,
ero we
e get optim
optimum
m for a single fin
tanh 32 sec h 2 = 0
3 = sinh cosh
Using
Solve to get

sinh 2 = 2sinh cosh

6 = sinh 2
= 1.4192

Optimum
p

However,, if a graphical
g p
solution is sought
g between
array,opt as a function of hwb/k from the relation
tanh 32 sec h 2 =

2h w b
k

We find an optimum array in the form of a linear relation

array,opt = 1.4192
1 4192 + 11.125
125

hwb
k

array,opt = 1.420

For b = 3 cm, k = 175 W/mK (auminium), h = 6 W/m2K

array,opt = 1.438

For b = 3 cm, k = 175 W/mK (auminium), h = 100 W/m2K

array,opt = 1.464

For b = 20 cm, k = 30 W/mK (cast iron), h = 6 W/m2K

Natural Convection Cooling

g
Elenbass suggested optimum Nusselt number for two vertical plate as

N u opt =
h opt

h opt z opt
k fluid

= 1.25

k fluid
= 1.25
z opt

O i
Optimum
single
i l fifin h
heat transfer
f with
i h = 1.4192
1 4192

q s,f
L

=(

1
2hkt 0 2

b tanh = 11.258
258b h 2 A p k

1
2

Total optimum heat transfer rate from the fin array is

q s,f q
q total
W
2
= n
+
=
1.258

b
opt A p k

L
L z opt + t 0
L

1
2

qw
= h w z b
L

+ h opt z opt b

Optimum
p
heat transfer
Using

1/ 2

kt o
b o =

2h

h opt = 1.25

k fluid
z opt

Bar -Cohen and Rohsenow

z opt
L
z opt
L

1
2.3Ra L4

1
2.714Ra L4

with Ap = boto
1
2

q total
LWb

k kt
0.8063 fluid 1 0 + 1.25k fluid
Ra 4 L
L

2.714Ra L

1
4L +

t0

where
Ra L =

g ( T0 T ) L

Optimum
p
spacing
p
g
Assuming the heat transfer from the interfin area between the fins is
negligible, following Eq.
qs,f q
q total
W
2
= n
+
Apk
1.258b h opt
=

+
L
L
L
z
t

opt
0

simplifies to

1.258 h opt kt 0
q total

LWb
z opt + t 0

1
2

+ h opt z opt b

1
2

Differentiating
Diff
i i the
h above
b
E
Eq. w.r.t. to and
d setting
i the
h d
derivative
i i to zero
provides the optimum spacing for the maximized heat transfer rate

z opt t o

Problem

A heat sink for an avionic electric package cooling is to be designed

to maintain the base temperature below 100C. The base cold plate
has a width W = 50 mm and length L = 30 mm. Forced air is drawn b
a fan at a velocity of U = 1.5 m/s and at the ambient air temperature
off 20C.
C N
Non-optimum
ti
d
design
i iis allowed
ll
d tto accommodate
d t th
these
requirements. For aluminium properties use density of 2702 kg/m3
and thermal conductivity of 177 W/mk.
D
Determine
t
i th
the maximum
i
optimum
ti
di
dimension
i ffor th
the h
heatt sink
i k providing
idi th
the
number of fins, the fin thickness, the fin spacing, the profile length, the heat
dissipation, overall efficiency and thermal resistance.
The device now requires a mass of fins to be less than 15 grams and the profile
length to ne less than 20 mm. With these constraints, design the fin array again.

z opt

1
3.24 Re
R L2

1
P 4
Pr

Find
=
L
Find hL
A
Assume
for
f a single
i l fifin.
Optimize heat transfer rate as a function of
to.
1/ 2
kt
o
=

o
Find
2h
Volume of a fin Val(to)=Lboto
Number of fins nf(to)=W/(zopt + to)

Total mass of the fin array as a function of to

mal(to)=nf(to)alVal(to)
Heat transfer rate from a single fin
Heat transfer rate from the interfin area
Total heat transfer rate
Fin effectiveness
Total area
Overall surface efficiency
Overall thermal resistance