Ansys Icepak Tutorials 2021 R2

Ansys Icepak Tutorials
ANSYS, Inc. Release 2021 R2

Southpointe July 2021
2600 Ansys Drive
Canonsburg, PA 15317 ANSYS, Inc. and
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Table of Contents
1. Using This Manual ................................................................................................................................... 1
1.1. What’s In This Manual ........................................................................................................................ 1
1.2. How To Use This Manual .................................................................................................................... 1
1.2.1. For the Beginner ...................................................................................................................... 1
1.2.2. For the Experienced User .......................................................................................................... 1
1.3.Typographical Conventions Used In This Manual ................................................................................ 2
1.4. Mouse Conventions Used In This Manual ........................................................................................... 2
1.5. When To Call Your Ansys Icepak Support Engineer ............................................................................. 2
2. Finned Heat Sink ..................................................................................................................................... 5
2.1. Introduction ..................................................................................................................................... 5
2.2. Prerequisites ..................................................................................................................................... 5
2.3. Problem Description ......................................................................................................................... 5
2.4. Step 1: Create a New Project .............................................................................................................. 6
2.5. Step 2: Build the Model ..................................................................................................................... 7
2.6. Step 3: Generate a Mesh .................................................................................................................. 21
2.7. Step 4: Physical and Numerical Settings ........................................................................................... 28
2.8. Step 5: Save the Model .................................................................................................................... 33
2.9. Step 6: Calculate a Solution ............................................................................................................. 33
2.10. Step 7: Examine the Results ........................................................................................................... 36
2.11. Step 8: Summary ........................................................................................................................... 48
2.12. Step 9: Additional Exercise ............................................................................................................. 50
3. RF Amplifier ........................................................................................................................................... 51
3.1. Introduction ................................................................................................................................... 51
3.2. Prerequisites ................................................................................................................................... 51
3.3. Problem Description ....................................................................................................................... 51
3.4. Step 1: Create a New Project ............................................................................................................ 52
3.5. Step 2: Build the Model ................................................................................................................... 53
3.6. Step 3: Create Assemblies ................................................................................................................ 71
3.7. Step 4: Generate a Mesh .................................................................................................................. 73
3.8. Step 5: Physical and Numerical Settings ........................................................................................... 77
3.9. Step 6: Save the Model .................................................................................................................... 84
3.10. Step 7: Calculate a Solution ........................................................................................................... 85
3.11. Step 8: Examine the Results ........................................................................................................... 89
3.12. Step 9: Summary ........................................................................................................................... 99
4. Use of Parameterization to Optimize Fan Location ............................................................................ 103
4.1. Introduction ................................................................................................................................. 103
4.2. Prerequisites ................................................................................................................................. 103
4.3. Problem Description ..................................................................................................................... 104
4.4. Step 1: Create a New Project .......................................................................................................... 104
4.5. Step 2: Build the Model ................................................................................................................. 105
4.6. Step 3: Creating Separately Meshed Assemblies ............................................................................. 119
4.7. Step 4: Generate a Mesh ................................................................................................................ 120
4.8. Step 5: Setting up the Multiple Trials .............................................................................................. 122
4.9. Step 6: Creating Monitor Points ..................................................................................................... 124
4.10. Step 7: Physical and Numerical Setting ......................................................................................... 125
4.11. Step 8: Save the Model ................................................................................................................ 127
4.12. Step 9: Calculate a Solution .......................................................................................................... 127
4.13. Step 10: Examine the Results ....................................................................................................... 128
4.14. Step 11: Reports .......................................................................................................................... 130
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4.15. Step 12: Summary ....................................................................................................................... 131

4.16. Step 13: Additional Exercise to Model Higher Altitude Effect ......................................................... 132
5. Cold-Plate Model with Non-Conformal Meshing ................................................................................ 135
5.1. Introduction ................................................................................................................................. 135
5.2. Prerequisites ................................................................................................................................. 135
5.6. Step 3: Create a Separately Meshed Assembly ................................................................................ 141
5.8. Step 5: Physical and Numerical Settings ......................................................................................... 144
5.9. Step 6: Save the Model .................................................................................................................. 147
5.11. Step 8: Examine the Results ......................................................................................................... 147
5.12. Step 9: Summary ......................................................................................................................... 148
5.13. Step 10: Additional Exercise ......................................................................................................... 149
6. Heat-Pipe Modeling and Nested Non-Conformal Meshing ................................................................ 151
6.1. Introduction ................................................................................................................................. 151
6.2. Prerequisites ................................................................................................................................. 151
6.6. Step 3: Create Nested Non-conformal Mesh Using Assemblies ........................................................ 158
6.12. Step 9: Summary ......................................................................................................................... 166
7. Non-Conformal Mesh .......................................................................................................................... 169
7.1. Introduction ................................................................................................................................. 169
7.2. Prerequisites ................................................................................................................................. 169
7.6. Step 3: Generate a Conformal Mesh ............................................................................................... 173
7.9. Step 6: Calculate a Solution ........................................................................................................... 176
7.11. Step 8: Add an Assembly to the Model ......................................................................................... 177
7.12. Step 9: Generate a Non-conformal Mesh ...................................................................................... 179
7.13. Step 10: Save the Model .............................................................................................................. 181
7.14. Step 11: Calculate a Solution ........................................................................................................ 181
7.16. Step 13: Summary ....................................................................................................................... 183
8. Mesh and Model Enhancement Exercise ............................................................................................. 185
8.1. Objective ...................................................................................................................................... 185
8.2. Prerequisites ................................................................................................................................. 185
8.3. Skills Covered ............................................................................................................................... 185
8.4. Training Method Used ................................................................................................................... 186
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8.5. Loading the Model ........................................................................................................................ 186

8.6. A 15 Minute Exploration ................................................................................................................ 186
8.7. Step-by-Step Approach ................................................................................................................. 186
8.8. Modification 1: Non-Conformal Mesh of the Heat Sink and Components ........................................ 188
8.9. Modification 2: Non-Conformal Mesh for the hi-flux-comps Cluster ................................................ 190
8.10. Modification 3: A Super Assembly ................................................................................................ 195
8.11. Modification 4: Separation Tolerance and Minimum Gap Settings ................................................. 196
8.12. Additional Exercise: Local Mesh Refinement and Comparisons Between the Non-Conformal and
Conformal Meshes .............................................................................................................................. 199
8.13. Conclusion .................................................................................................................................. 200
9. Loss Coefficient for a Hexa-Grille ........................................................................................................ 203
9.1. Introduction ................................................................................................................................. 203
9.2. Prerequisites ................................................................................................................................. 203
9.6. Step 3: Define Parameters and Trials ............................................................................................... 206
9.12. Step 9: Summary ......................................................................................................................... 221
10. Inline and Staggered Heat Sinks Comparison .................................................................................. 223
10.1. Introduction ............................................................................................................................... 223
10.2. Prerequisites ............................................................................................................................... 223
10.3. Problem Description ................................................................................................................... 223
10.4. Step 1: Create a New Project ........................................................................................................ 224
10.5. Step 2: Build the Model ................................................................................................................ 225
10.6. Step 3: Define Design Variables .................................................................................................... 226
10.7. Step 4: Define Parametric Runs and Assign Primary Functions ...................................................... 228
10.8. Step 5: Generate a Mesh .............................................................................................................. 232
10.9. Step 6: Physical and Numerical Settings ....................................................................................... 233
10.11. Step 8: Monitor Points ............................................................................................................... 235
10.13. Step 10: Examine the Results ...................................................................................................... 236
10.14. Step 11: Summary ..................................................................................................................... 244
11. Minimizing Thermal Resistance ........................................................................................................ 245
11.1. Introduction ............................................................................................................................... 245
11.2. Prerequisites ............................................................................................................................... 245
11.6. Step 3: Define Design Variables .................................................................................................... 247
11.10. Step 7: Define Primary, Compound, and Objective Functions ....................................................... 251
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11.13. Step 10: Optimization in DesignXplorer ...................................................................................... 256

11.14. Step 11: Summary ..................................................................................................................... 262
11.15. Step 12: Additional Exercise ....................................................................................................... 263
12. Radiation Modeling .......................................................................................................................... 265
12.1. Introduction ............................................................................................................................... 265
12.2. Prerequisites ............................................................................................................................... 265
12.8. Step 5: Solving the Model Without Radiation ................................................................................ 276
12.10. Step 7: Calculate a Solution: No Radiation ................................................................................... 280
12.11. Step 8: Surface to Surface (S2S) Radiation Model ........................................................................ 280
12.12. Step 9: Discrete Ordinates (DO) Radiation Model ........................................................................ 282
12.13. Step 10: Ray-Tracing Radiation Model ........................................................................................ 283
12.15. Step 12: Summary ..................................................................................................................... 287
13. Transient Simulation ......................................................................................................................... 289
13.1. Introduction ............................................................................................................................... 289
13.2. Prerequisites ............................................................................................................................... 289
13.10. Step 8: Generate a Summary Report ........................................................................................... 297
13.12. Step 10: Examine Transient Results in CFD-Post .......................................................................... 303
13.13. Step 10: Summary ..................................................................................................................... 308
14. Zoom-In Modeling in Ansys Workbench ........................................................................................... 311
14.1. Introduction ............................................................................................................................... 311
14.2. Prerequisites ............................................................................................................................... 311
14.11. Step 8: Create a Zoom-In Model ................................................................................................. 321
14.12. Step 9: Edit the Zoom-in Model .................................................................................................. 325
14.13. Step 10: Mesh the Zoom-In Model ............................................................................................. 327
14.14. Step 11: Zoom-In Physical and Numerical Settings ...................................................................... 328
14.15. Step 12: Examine the Zoom-in Results ........................................................................................ 329
14.16. Step 13: Summary ..................................................................................................................... 330
14.17. Step 14: Additional Exercise 1 .................................................................................................... 331
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14.18. Step 15: Additional Exercise 2 .................................................................................................... 331

15. IDF Import ......................................................................................................................................... 335
15.1. Introduction ............................................................................................................................... 335
15.2. Prerequisites ............................................................................................................................... 335
15.6. Step 3: Component Filtration Alternatives .................................................................................... 342
15.7. Step 4: Component Models Alternatives ...................................................................................... 344
15.8. Step 5: Summary ......................................................................................................................... 345
16. Trace Layer Import for Printed Circuit Boards ................................................................................... 347
16.1. Introduction ............................................................................................................................... 347
16.2. Prerequisites ............................................................................................................................... 348
16.6. Conduction Only Model (PCB Without the Components) .............................................................. 361
16.8. Step 2: Set Physical and Numerical Values .................................................................................... 362
16.12. PCB With the Actual Components Under Forced Convection ...................................................... 365
16.13. Step 1: Generate a Mesh ............................................................................................................ 365
16.14. Step 2: Set Physical and Numerical Values .................................................................................. 366
16.17. Summary .................................................................................................................................. 367
16.18. Additional Exercise 1 ................................................................................................................. 367
17. Joule/Trace Heating .......................................................................................................................... 369
17.1. Introduction ............................................................................................................................... 369
17.2. Prerequisites ............................................................................................................................... 369
17.11. Step 8: Summary ....................................................................................................................... 386
18. Microelectronics Packages - Compact models .................................................................................. 387
18.1. Introduction ............................................................................................................................... 387
18.2. Prerequisites ............................................................................................................................... 387
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18.11. Step 8: Summary ....................................................................................................................... 407
18.12. Step 9: Additional Exercise ......................................................................................................... 407
19. Multi-Level Meshing .......................................................................................................................... 409
19.1. Objective .................................................................................................................................... 409
19.2. Prerequisites ............................................................................................................................... 409
19.3. Skills Covered .............................................................................................................................. 409
19.4. Loading the Model ...................................................................................................................... 409
19.5. Step-by-Step Approach ............................................................................................................... 410
19.6. Modification 1: Multi-Level Meshing of the Fan_Guide ................................................................. 413
19.7. Modification 2: Multi-Level Mesh of the Sheetmetal_hs_assy.1 ..................................................... 414
19.8. Generate a Mesh ......................................................................................................................... 415
19.9. Conclusion .................................................................................................................................. 419
20. Characterizing a BGA-package by Utilizing ECAD Files .................................................................... 421
20.1. Introduction ............................................................................................................................... 421
20.2. Prerequisites ............................................................................................................................... 421
20.11. Step 8: Summary ....................................................................................................................... 434
21. Zero Slack with Non-Conformal Meshing ......................................................................................... 435
21.1. Introduction ............................................................................................................................... 435
21.2. Prerequisites ............................................................................................................................... 435
21.5. Step 2: Default Units .................................................................................................................... 437
21.7. Step 4: Import Traces ................................................................................................................... 437
21.8. Step 5: Add Slack Values .............................................................................................................. 439
21.9. Step 6: Generate Mesh (with Slack Values) .................................................................................... 440
21.10. Step 7: Zero Slack ...................................................................................................................... 441
21.11. Step 8: Generate Mesh (with Zero Slack) ..................................................................................... 443
21.12. Step 9: Physical and Numerical Settings ..................................................................................... 443
21.13. Step 10: Save the Model ............................................................................................................. 444
21.14. Step 11: Calculate a Solution ...................................................................................................... 444
21.16. Step 13: Summary ..................................................................................................................... 445
22. Ansys Icepak - Ansys Workbench Integration Tutorial ...................................................................... 447
22.1. Introduction ............................................................................................................................... 447
22.2. Prerequisites ............................................................................................................................... 447
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22.10. Step 7: Examine the Results with CFD-Post ................................................................................. 459
22.11. Step 8: Thermo-Mechanical Structural Analysis ........................................................................... 462
22.12. Step 9: Summary ....................................................................................................................... 463
23. Postprocessing Using Ansys CFD-Post .............................................................................................. 465
23.1. Introduction ............................................................................................................................... 465
23.2. Prerequisites ............................................................................................................................... 465
23.5. Step 2: Parametric Trials and Solver Settings ................................................................................. 470
23.7. Step 4: Postprocessing Using Ansys CFD-Post ............................................................................... 472
23.8. Step 5: Comparison Study ............................................................................................................ 501
23.9. Step 6: Summary ......................................................................................................................... 507
24. High Density Datacenter Cooling ..................................................................................................... 509
24.1. Introduction ............................................................................................................................... 509
24.2. Prerequisites ............................................................................................................................... 509
24.5. Step 2: Set Preferences ................................................................................................................ 511
24.8. Step 5: Create Monitor Points ....................................................................................................... 540
24.13. Step 10: Additional Exercise: Visualize and analyze the results in Ansys CFD-Post ......................... 552
24.14. Step 11: Summary ..................................................................................................................... 552
25. Design Modeler - Electronics ............................................................................................................ 553
25.1. Introduction ............................................................................................................................... 553
25.2. Prerequisites ............................................................................................................................... 553
25.6. Step 3: Add Shortcuts to the Toolbar ............................................................................................ 556
25.7. Step 4: Edit the Model for Ansys Icepak ........................................................................................ 558
25.8. Step 5: Opening the Model in Ansys Icepak .................................................................................. 575
25.9. Step 6: Summary ......................................................................................................................... 577
26. CFD Modeling and Analysis of an Avionics Box ............................................................................... 579
26.1. Introduction ............................................................................................................................... 579
26.2. Prerequisites ............................................................................................................................... 579
26.3. Create a New Ansys Icepak Project ............................................................................................... 579
26.4. Create a Support for the Box and Resize Cabinet .......................................................................... 581
26.5. Set Up the Model for Non-conformal Meshing ............................................................................. 586
26.6. Generate the Mesh ...................................................................................................................... 592
26.7. Power and Material Inputs ........................................................................................................... 595
26.8. Fan Inputs ................................................................................................................................... 596
26.9. Physical and Numerical Settings .................................................................................................. 597
26.10. Calculate a Solution ................................................................................................................... 603
26.11. Examine the Results .................................................................................................................. 604
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26.12. Additional Exercises .................................................................................................................. 613

26.13. Setup for Transient Analysis – Forced Convection Mode ............................................................. 615
27. SpaceClaim - Icepak Coupling ........................................................................................................... 619
27.1. Introduction ............................................................................................................................... 619
27.2. Prerequisites ............................................................................................................................... 619
27.5. Clean Up the Geometry and Translate to Icepak Objects ............................................................... 620
27.6. Open Icepak to Finalize Model Setup ........................................................................................... 641
27.7. Generate a Mesh ......................................................................................................................... 646
27.8. Step 6: Summary ......................................................................................................................... 647
28. Translation of MCAD Geometry to Icepak Native Geometry Using Ansys DesignModeler .............. 649
28.1. Introduction ............................................................................................................................... 649
28.2. Prerequisites ............................................................................................................................... 649
28.3. Tutorial Outline ........................................................................................................................... 649
28.4. Part 1: General Topics .................................................................................................................. 650
28.5. Ansys Workbench Project Schematic ........................................................................................... 651
28.6. DesignModeler ........................................................................................................................... 653
28.7. CAD Model Import ...................................................................................................................... 653
28.8. PART 2: Model Conversion From CAD to Icepak ............................................................................ 655
28.9. Ansys DesignModeler- Electronics ............................................................................................... 655
28.10. Simplify - Level 0 ....................................................................................................................... 657
28.11. Slice Tool in DM ......................................................................................................................... 660
28.12. Simplify - Level 1 ....................................................................................................................... 664
28.13. Simplify - Level 2 ....................................................................................................................... 667
28.14. Simplification into Icepak Objects – Level 3 ................................................................................ 667
28.15. Conclusion ................................................................................................................................ 671
29. Simple Geometry Import Using SpaceClaim ..................................................................................... 673
29.1. Introduction ............................................................................................................................... 673
29.2. Prerequisites ............................................................................................................................... 673
29.5. Simplify - Level 0 ......................................................................................................................... 675
29.6. Split Body Tool in SpaceClaim ...................................................................................................... 678
29.7. Simplify - Level 1 ......................................................................................................................... 680
29.8. Simplify - Level 2 ......................................................................................................................... 684
29.9. Simplification into Icepak Objects – Level 3 .................................................................................. 684
29.10. Step 6: Summary ....................................................................................................................... 687
30.Translation of System-Level MCAD Geometry to Icepak Native Geometry Using Ansys DesignModel-
er ............................................................................................................................................................. 689
30.1. Introduction ............................................................................................................................... 689
30.2. Prerequisites ............................................................................................................................... 689
30.3. Tutorial Outline ........................................................................................................................... 689
30.4. Model Description ...................................................................................................................... 690
30.5. Getting Started – Ansys Workbench, Project Schematic ................................................................ 690
30.6. Getting Started - Ansys DesignModeler ....................................................................................... 693
30.7. Import of CAD Geometry ............................................................................................................ 693
30.8. Initial Model Review .................................................................................................................... 694
30.9. CAD Geometry Information and Repair Utilities ........................................................................... 696
30.10. Suppress Non-Essential Bodies .................................................................................................. 697
30.11. Functionality Based Grouping ................................................................................................... 698
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30.12. Simple Shapes vs. Complex Shapes ............................................................................................ 699

30.13. Translation of CAD Bodies to Ansys Icepak ................................................................................. 701
30.14. Summary .................................................................................................................................. 742
31. MRF Tutorial ...................................................................................................................................... 743
31.1. Introduction ............................................................................................................................... 743
31.2. Prerequisites ............................................................................................................................... 743
31.3. Opening the Project .................................................................................................................... 744
31.4. Modifying the Geometry ............................................................................................................. 745
31.5. Generating the Mesh ................................................................................................................... 748
31.6. Examine the Mesh ....................................................................................................................... 752
31.7. Solution Settings for MRF Fan Model ........................................................................................... 754
31.8. Post-processing the Results ......................................................................................................... 758
31.9. BONUS SECTION: Comparing MRF to 3D Icepak Fans .................................................................... 760
32. Modeling an Airborne Electronics System at Altitude ...................................................................... 761
32.1. Introduction ............................................................................................................................... 761
32.2. Opening the Project .................................................................................................................... 762
32.3. Adding the Fins ........................................................................................................................... 763
32.4. Modeling the effects of Altitudes ................................................................................................. 768
32.5. Summary .................................................................................................................................... 775
33. Maxwell and Ansys Icepak Coupling Tutorial ................................................................................... 777
33.1. Introduction ............................................................................................................................... 777
33.2. Prerequisites ............................................................................................................................... 777
33.11. Step 8: Iterate in Workbench ...................................................................................................... 800
33.12. Step 9: Examine Feedback Iterator Run Results ........................................................................... 803
33.13. Step 10: Summary ..................................................................................................................... 806
34. Icepak – HFSS Coupling ..................................................................................................................... 807
34.1. Introduction ............................................................................................................................... 807
34.2. Prerequisites ............................................................................................................................... 807
34.8. Step 5: Volume/Surface Mapping ................................................................................................. 812
34.12. Step 9: Summary ....................................................................................................................... 821
35. SIwave - Icepak Coupling .................................................................................................................. 823
35.1. Introduction ............................................................................................................................... 823
35.2. Prerequisites ............................................................................................................................... 823
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35.5. Step 2: Run an SIwave Simulation ................................................................................................ 824

35.6. Step 3: Run an Icepak Simulation (Conduction Only) .................................................................... 838
35.7. Step 3: Run an Icepak Simulation (Forced Convection) .................................................................. 842
35.8. Step 4: Run a Single Board Setup in Icepak ................................................................................... 847
35.9. Step 5: Run a Multi-Board Setup in Icepak .................................................................................... 868
35.10. Step 6: Summary ....................................................................................................................... 872
36. TEC Macro Tutorial ............................................................................................................................. 873
36.1. Introduction ............................................................................................................................... 873
36.2. Prerequisites ............................................................................................................................... 873
36.6. Step 3: Creating Separately Meshed Assemblies ........................................................................... 887
36.8. Step 5: Create Monitor Points ....................................................................................................... 891
36.9. Define Physical and Numerical Settings ....................................................................................... 892
36.11. Calculate a Solution ................................................................................................................... 893
36.12. Examine the Results .................................................................................................................. 897
36.13. Step 6: Summary ....................................................................................................................... 900
37. Icepak-Twin Builder Coupling ........................................................................................................... 901
37.1. Introduction ............................................................................................................................... 901
37.2. Prerequisites ............................................................................................................................... 901
37.4. Step 1: Unpack the TZR File .......................................................................................................... 902
37.5. Step 2: Set up the State-space Trials ............................................................................................. 904
37.6. Step 3: Enter Inputs and Outputs for State-space .......................................................................... 905
37.7. Step 4: Run a Steady State Solution ............................................................................................. 907
37.8. Step 5: Run Transient Trials ........................................................................................................... 909
37.9. Step 6: Create the ROM in Twin Builder ......................................................................................... 911
37.10. Step 7: Place the ROM in Twin Builder ......................................................................................... 915
37.11. Step 8: Enable Outputs .............................................................................................................. 915
37.12. Step 9: Specify Inputs ................................................................................................................ 916
37.13. Step 10: Plot Outputs ................................................................................................................. 919
37.14. Step 11: Simulate ROM .............................................................................................................. 921
37.15. Step 6: Summary ....................................................................................................................... 923
38. CTM Import and RedHawk Back Annotation .................................................................................... 925
38.1. Introduction ............................................................................................................................... 925
38.2. Unpack the Ansys Icepak Project ................................................................................................. 926
38.3. Set Project Units .......................................................................................................................... 928
38.4. Check Custom Material Properties ............................................................................................... 929
38.5. Review the Package Object ......................................................................................................... 932
38.6. Import RedHawk CTM Profile ....................................................................................................... 937
38.7. Generate the Mesh ...................................................................................................................... 943
38.8. Run the Simulation ...................................................................................................................... 948
38.9. Post-Process the Solution ............................................................................................................ 951
38.10. Export Data ............................................................................................................................... 957
38.11. Summary .................................................................................................................................. 958
Index ........................................................................................................................................................ 961
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List of Figures
2.1. Problem Specification ............................................................................................................................. 6
2.2. Completed Model for the Finned Heat Sink ........................................................................................... 19
2.3. Show objects by type Panel ................................................................................................................... 19
2.4. Display of Conducting Thick Plate Objects ............................................................................................. 20
2.5. Partial Table of Summary Report for Blocks ............................................................................................ 21
2.6. Coarse Mesh on the Y-Z Plane ............................................................................................................... 26
2.7. Fine and Coarse Mesh on the Y-Z Plane ................................................................................................. 27
2.8. Display mesh Option ............................................................................................................................. 28
2.9. Basic settings panel .............................................................................................................................. 29
2.10. Problem setup wizard panel at step 1 of 14 .......................................................................................... 30
2.11. Problem setup wizard at step 5 of 14 ................................................................................................... 31
2.12. Problem setup wizard at step 14 of 14 ................................................................................................. 32
2.13. Basic parameters panel ....................................................................................................................... 33
2.14. Solve Panel ......................................................................................................................................... 34
2.15. Plot of Solution Residuals .................................................................................................................... 35
2.16. Plane cut Panel for cut-velocity ............................................................................................................ 37
2.17. Plane cut vectors Panel for cut-velocity ................................................................................................ 37
2.18. Velocity Vectors on the Fin Side of the Enclosure .................................................................................. 38
2.19.Temperature Contours on the Fin Side of the Enclosure ........................................................................ 40
2.20. Pressure Contours and Velocity Vectors on the Fin Side of the Enclosure ............................................... 41
2.21. Temperature Contours on the Five Devices .......................................................................................... 44
2.22. Temperature Contours on the Backing Plate ........................................................................................ 45
2.23. Example of Transparency Feature with Multiple Plane cut Contours ...................................................... 46
2.24. Report summary data Panel ................................................................................................................ 48
3.1. Schematic of the RF Amplifier ............................................................................................................... 52
3.2. The Cabinet Geometry Tab Panel ........................................................................................................... 54
3.3. The Cabinet Boundary Panel ................................................................................................................. 55
3.4. The Enclosure Panel .............................................................................................................................. 56
3.5. Schematic Showing Edge Identities for Alignment ................................................................................. 57
3.6. Geometry with Wall .............................................................................................................................. 58
3.7. The Walls Panel ..................................................................................................................................... 59
3.8. The Printed circuit boards Panel ............................................................................................................ 60
3.9. The Sources Panel ................................................................................................................................. 62
3.10.The Copy source device Panel .............................................................................................................. 63
3.11. Geometry with Devices ....................................................................................................................... 64
3.12. The Heat sinks Panel ............................................................................................................................ 65
3.13. Search Fan library Panel ...................................................................................................................... 67
3.14. The Fans Panel .................................................................................................................................... 68
3.15. The Final Geometry ............................................................................................................................. 69
3.16. Show objects by type Panel ................................................................................................................. 70
3.17. Displaying Objects of Type Source ....................................................................................................... 70
3.18. Two Assemblies .................................................................................................................................. 72
3.19. Fan Assemblies Panel .......................................................................................................................... 74
3.20. The Mesh control Panel ....................................................................................................................... 75
3.21. Coarse and Fine Mesh ......................................................................................................................... 77
3.22. The Basic settings Panel ...................................................................................................................... 78
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3.28. Basic parameters panel ....................................................................................................................... 83
3.29. Panel of Power and temperature limit setup ........................................................................................ 84
3.30. The Modify point Panel ....................................................................................................................... 85
3.31. Convergence Plot ................................................................................................................................ 87
3.32. Monitor Plot - Temperature ................................................................................................................. 88
3.33. Monitor Plot - Velocity ......................................................................................................................... 88
3.34. Object face Panel ................................................................................................................................ 90
3.35. Temperature Contours on the Heat Sink Object Face ............................................................................ 91
3.36. Plane cut Panel ................................................................................................................................... 92
3.37. Plane Cut of Velocity Vector Field ......................................................................................................... 93
3.38. Temperature Isosurface Contour of 55°C for Sources ............................................................................ 94
3.39. Temperature Contours on Isosurface of Speed 4 m/s ............................................................................ 95
3.40. Isosurface Panel with Transparency Enabled ........................................................................................ 95
3.41. Concurrent Visualization of Semi-Transparent Isosurface and Opaque Plane cut ................................... 96
3.42. Report summary data Panel ................................................................................................................ 98
3.43. Variation Plot of UY Velocity Versus Z Coordinate ................................................................................. 99
4.1. Schematic of the Geometry ................................................................................................................. 104
4.2. The Param value Panel ........................................................................................................................ 105
4.3. The Fans Panel (Properties Tab) ............................................................................................................ 106
4.4. The Fan Curve Panel ............................................................................................................................ 107
4.5. Model with Fan ................................................................................................................................... 108
4.6. Grille Panel (Properties Tab) ................................................................................................................. 110
4.7. Model with Fan and Grille .................................................................................................................... 111
4.8. Walls Panel (Properties Tab) ................................................................................................................. 112
4.9. Model with Wall Added ....................................................................................................................... 113
4.10. The Individual side specification ........................................................................................................ 114
4.11. Creation of Solid Blocks ..................................................................................................................... 115
4.12. The Properties Panel .......................................................................................................................... 116
4.13. Final Model ....................................................................................................................................... 118
4.14. Partial Table of Summary Report for Blocks ........................................................................................ 119
4.15. Graph of Face alignment ................................................................................................................... 121
4.16. The Parameters and optimization Panel (Design variables Tab) ........................................................... 122
4.17. The Parameters and optimization Panel (Trials Tab) ............................................................................ 124
4.18.The Modify point Panel ...................................................................................................................... 125
4.19. The Basic settings Panel ..................................................................................................................... 125
4.20. The Basic parameters Panel ............................................................................................................... 127
4.21.Trial 1 Vector Plots at Constant Z Plane Cut ......................................................................................... 128
4.22.Trial 2 Vector Plots at Constant Z Plane Cut ......................................................................................... 129
4.23. Trial 1 Temperature Contours on Blocks and PCB (wall.1) .................................................................... 129
4.24. Trial 2 Temperature Contours on Blocks and PCB (wall.1) .................................................................... 130
5.1. The Cold-Plate Model .......................................................................................................................... 136
5.2. Mesh control Panel Settings ................................................................................................................ 143
5.3. Switching on Gravity and Turbulent Flow ............................................................................................. 145
5.4. Basic and Advanced Solver Settings ..................................................................................................... 146
6.1. Heat-pipe Tutorial Base Model ............................................................................................................. 152
6.2. Orthotropic Material Properties ........................................................................................................... 154
6.3. Nonuniform Cylinder .......................................................................................................................... 157
6.4. Model with Heat Pipe and Heat Sink .................................................................................................... 158
6.5. Mesh control Panel ............................................................................................................................. 161
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6.6. Turbulent Flow and Initial Z Velocity .................................................................................................... 162

6.7. Basic settings Panel ............................................................................................................................. 163
6.8.Temperature Contours on All Blocks (face.1) ......................................................................................... 165
6.9. Velocity Vector Field Around Fan and Heat Sink (cut.1) ......................................................................... 166
7.1. Problem Specification ......................................................................................................................... 170
7.2. Openings Panel for Wall Min z ............................................................................................................. 171
7.3. Grille Properties Specifications ............................................................................................................ 172
7.4. Heat sinks Panel (Specifications for Geometry and Properties) .............................................................. 173
7.5. Conformal Mesh, Central Y Plane ......................................................................................................... 174
7.6. Slack Values and Mesh Controls in the Separately Mesh Assembly ........................................................ 178
7.7. The Source and Heat Sink in a Separately Meshed Assembly ................................................................ 179
7.8. Non-conformal Mesh .......................................................................................................................... 180
7.9. Residuals Plot for the Non-Conformal Mesh ......................................................................................... 182
7.10. Report summary data for the Non-Conformal Mesh ........................................................................... 183
8.1. A Mesh Cut Plane View of the Given Model When Meshed Without Modifications ................................. 187
8.2. Slack Values for HS-asy ........................................................................................................................ 189
8.3. Comparison Between the Non-Conformal Mesh and the Conformal Mesh ............................................ 190
8.4. Mesh Bleeding After 1 Non-Conformal Region ..................................................................................... 191
8.5. Objects for Assembly hfc-asy ............................................................................................................... 192
8.6. Slack Settings for Assembly hfc-asy ..................................................................................................... 193
8.7. Mesh Bleeding Reduction due to Modification 2 .................................................................................. 194
8.8. Mesh Bleeding from the Boards ........................................................................................................... 195
8.9. Cut Plane View of Recursive Embedded Mesh ...................................................................................... 196
8.10. Minimum gap Settings ...................................................................................................................... 197
8.11. Separation Warning .......................................................................................................................... 198
8.12. Per-object Meshing Parameters ......................................................................................................... 200
9.1. Problem Specification ......................................................................................................................... 204
9.2. Loaded Model ..................................................................................................................................... 205
9.3. Mesh on the X-Z Plane ........................................................................................................................ 215
9.4. Volume Mesh of Object block.1 ........................................................................................................... 216
9.5. Kfact vs Re Plot ................................................................................................................................... 221
10.1. Problem Specification ....................................................................................................................... 224
10.2. Mesh control Panel Settings .............................................................................................................. 233
10.3. Basic parameters Panel Settings ........................................................................................................ 234
10.4. Monitor Points .................................................................................................................................. 235
10.5. The Parametric trials Panel .............................................................................................................. 236
10.6. Plane cut vectors Panel ...................................................................................................................... 237
10.7. Velocity Vectors at the Exit Region of the Heat Sink ............................................................................ 238
10.8. Clipped Plane Cut ............................................................................................................................. 240
10.9. Plane cut particles Panel .................................................................................................................... 241
10.10. Forward Particle Traces .................................................................................................................... 242
10.11. Opening Particle Traces ................................................................................................................... 243
11.2. The Optimization run Panel ............................................................................................................... 256
11.3. finCount Setup .................................................................................................................................. 260
11.4. finThick Setup ................................................................................................................................... 261
11.5. Design of Experiments ...................................................................................................................... 262
11.6. Optimization Constraints ................................................................................................................... 262
12.1. Dimensions of the Cabinet and the Boundary Condition Specifications .............................................. 266
12.2. Dimensions of the PCB ...................................................................................................................... 267
12.3. Specifying material.1 as PCB Solid Material ........................................................................................ 268
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12.4. Dimensions of the hs-base ................................................................................................................ 269

12.5. Heat Sink Fin Dimensions .................................................................................................................. 270
12.6. Source at the Bottom on the Heat Sink .............................................................................................. 271
12.7. Schematic of the Model ..................................................................................................................... 272
12.8. Meshing Parameters for assembly.1 ................................................................................................... 274
12.9. Global Mesh Control Parameters ........................................................................................................ 275
12.10. Basic parameters Panel .................................................................................................................... 277
12.11. Basic settings Panel ......................................................................................................................... 278
12.12. Advanced solver setup Panel ........................................................................................................... 279
12.13. Temperature Results for the Model With Radiation Disabled ............................................................. 280
12.14. Form Factors of the PCB ................................................................................................................... 281
12.15. Enabling Radiation in Ansys Icepak Model ....................................................................................... 282
12.16.Temperature Results for the Surface to Surface Radiation Model ....................................................... 282
12.17. Temperature Results for the Discrete Ordinates Radiation Model ...................................................... 283
12.18. Temperature Results for the Ray-Tracing Radiation Model ................................................................ 283
12.19. Plane cuts on the Z = 20 mm plane for (a) radiation disabled (b) S2S radiation model (c) discrete ordinates
radiation model and (d) ray-tracing radiation model .................................................................................. 285
13.1. Setting up the Model as Transient ...................................................................................................... 290
13.2. Defining Transient Power for the Sources ........................................................................................... 292
13.3. Viewing the Variation of Power on the Sources with Time ................................................................... 293
13.4. Schematic of the Model ..................................................................................................................... 294
13.5. Basic settings Panel ........................................................................................................................... 296
13.6. Convergence Plot .............................................................................................................................. 297
13.7. Define summary report Panel ............................................................................................................ 298
13.8. Transient Temperature Contour and Velocity Distribution Results at Various Time Values ..................... 300
13.9. History plot ....................................................................................................................................... 303
13.10. CFD-Post ......................................................................................................................................... 304
13.11. Details of Auto Annotation .............................................................................................................. 305
13.12. Details of Temperature Contours ..................................................................................................... 306
13.13. TemperatureContours Display ......................................................................................................... 307
13.14. Timestep Selector Panel .................................................................................................................. 308
14.2. Ansys Workbench ............................................................................................................................. 313
14.3. Object Parameters in the Mesh control Panel ..................................................................................... 315
14.4. The Solve Panel ................................................................................................................................. 317
14.5. Object Face: face.1 (plate2.2 Temperature) ......................................................................................... 320
14.6. Plane Cut: cut.1 (Z Plane Through Center Velocity) .............................................................................. 321
14.7. The Zoom-in modeling Setup Panel ................................................................................................... 322
14.8. Zoom-in Box ..................................................................................................................................... 324
14.9. Project Schematic ............................................................................................................................. 325
14.10. Plates Panel for Object Chip (Geometry Tab) .................................................................................... 326
14.11. Schematic of the Completed Zoom-in Model ................................................................................... 327
14.12. Zoom-in Mesh control Panel ............................................................................................................ 328
14.13. Object Faces face.1 and face.2 ......................................................................................................... 330
14.14.Temperature Comparison: Zoom-in Model with Conformal Meshing vs. System with Non-conformal
Assembly .................................................................................................................................................. 333
15.1. IDF Import Menu ............................................................................................................................... 337
15.2. IDF import Panel - Load files .............................................................................................................. 337
15.3. IDF import Panel - Layout options ...................................................................................................... 338
15.4. IDF import Panel - Component filters ................................................................................................. 339
15.5. IDF import Panel - Component models .............................................................................................. 340
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15.6. IDF import Panel - Miscellaneous options .......................................................................................... 341

15.7. IDF Import Summary ......................................................................................................................... 341
15.8. IDF Imported Model with All Components ......................................................................................... 342
15.9. IDF Import Panel - Components filters: Filter by size/power ................................................................ 343
15.10. IDF Import Panel - Component filters: Filter by component type ....................................................... 343
15.11. Component selection Panel ............................................................................................................. 344
15.12. Set Component Property Using File ................................................................................................. 344
15.13. Manual Selection of Component Models ......................................................................................... 345
16.1. A11 Board Layout .............................................................................................................................. 354
16.2. Printed circuit boards [BOARD_OUTLINE.1] Panel ............................................................................... 355
16.3. Importing Trace Layout and Editing Layer Information ....................................................................... 357
16.4. Vias Information ................................................................................................................................ 358
16.5. Displaying Traces on the Board .......................................................................................................... 359
16.6. Trace Layout on the PCB with the Color by trace Option ..................................................................... 360
16.7. Displaying Trace Layers ..................................................................................................................... 360
16.8. Metal fractions display ...................................................................................................................... 361
16.9. Temperature Distribution on the PCB (mid-plane) .............................................................................. 364
16.10. K_Z Distribution on the PCB (mid-plane) .......................................................................................... 365
16.11. Top Surface Temperature Distribution: PCB With Imported Traces in Forced Convection .................... 367
17.1. Trace Heating Panel Selection and Options ........................................................................................ 372
17.2. Solid Block Created for Trace A3V3_2261 ........................................................................................... 373
17.3. Polygonal Trace Block ........................................................................................................................ 374
17.4. Joule Heating Power Panel ................................................................................................................ 375
17.5. Source Geometry Definitions ............................................................................................................. 376
17.8. Mesh Settings for the Trace Board ...................................................................................................... 378
17.9. Mesh control Panel ............................................................................................................................ 379
17.10. Linear Solver Settings ...................................................................................................................... 381
17.11. Solution Residuals ........................................................................................................................... 382
17.12. Trace Temperature Contours with Forced Convection ....................................................................... 384
17.13. Trace Electric Potential Contours with Forced Convection ................................................................. 385
18.2. Layout of the board to be analyzed .................................................................................................... 389
18.3. PCB Edit Form with input based on PCB information in the Table with Model Object Details above ..... 391
18.4. Window Selecting Multiple Objects for Simultaneous Edit .................................................................. 393
18.5. TO-220 Properties Tab ....................................................................................................................... 394
18.6. Package Search Criteria ..................................................................................................................... 396
18.7. Mesh control panel ........................................................................................................................... 400
18.8. Monitor Point Definition .................................................................................................................... 402
18.9. Solve panel ....................................................................................................................................... 403
18.10. Temperature Contours on pcb.1 ....................................................................................................... 404
18.11. Temperature Contour Plane Cut (Z plane through center) ................................................................. 405
18.12.Temperature Contour Plane Cut (Y plane through center) ................................................................. 406
18.13. Summary Report for Object 400-PBGA ............................................................................................. 407
19.1. Mesh of Flow Guide Without Multi-Level Meshing .............................................................................. 412
19.2. Mesh of Sheetmetal_HS Without Multi-Level Meshing ....................................................................... 413
19.3. Meshing Levels of the Fan Guide Objects ........................................................................................... 417
19.4. Surface Mesh of guide_sweep-0_1.1 .................................................................................................. 418
19.5. Surface Mesh of SheetMetal_HS ........................................................................................................ 419
20.1. The Packages Panel (Dimensions Tab) ................................................................................................ 423
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20.2. Display of Traces ............................................................................................................................... 425

20.3. Properties Tab of the Printed Circuit Boards Panel .............................................................................. 426
20.4. Geometry Window for Object Bottom ................................................................................................ 427
20.5. Specifying the Heat Transfer Coefficient on the Top Wall ..................................................................... 428
20.6. Mesh control Panel ............................................................................................................................ 429
20.7. Object face Panel .............................................................................................................................. 432
20.8.Temperature Contours on the Wirebonds (Top View) .......................................................................... 433
21.1. Problem Schematic ........................................................................................................................... 436
21.2. Package and Heatsink Assemblies ..................................................................................................... 443
22.1. Problem Schematic ........................................................................................................................... 448
22.2. Details of Simplify1 ........................................................................................................................... 450
22.3. The Final Model Display ..................................................................................................................... 453
22.4. Location Selector Panel ..................................................................................................................... 460
22.5. Contour 1 ......................................................................................................................................... 461
23.1. Quick Reference - CFD Post Interface ................................................................................................. 466
23.2. Quick Reference - Mouse Button Mapping (default) in CFD Post: ........................................................ 466
23.3. Problem Schematic - Graphics Card Model (two configurations) ......................................................... 467
23.4. Creating an Ansys Icepak Component ................................................................................................ 468
23.5. Renaming the Ansys Icepak Component Module ............................................................................... 468
23.6. Linking the Results (Ansys CFD-Post) Component to the Ansys Icepak Component ............................. 469
23.7. Final Project Schematic ..................................................................................................................... 469
23.8. Solution Trials ................................................................................................................................... 471
23.9. Details View for BoardANDComponents Surface Group ...................................................................... 472
23.10. Selection for the BoardANDComponents Surface Group .................................................................. 473
23.11. Listing of Surface Groups under User Locations and Plots ................................................................. 474
23.12. Selection for the CabinetSurfaces Surface Group ............................................................................. 474
23.13. Rendering Details for the CabinetSurfaces Surface Group ................................................................. 475
23.14. Updated Model ............................................................................................................................... 476
23.15. Setting Units in CFD Post ................................................................................................................. 477
23.16. Geometry Settings for TemperatureContours ................................................................................... 478
23.17. Settings for Default Legend View 1 .................................................................................................. 479
23.18. Modified Legend View ..................................................................................................................... 479
23.19. Geometry Settings for HeatFluxVectors ............................................................................................ 480
23.20. Display of HeatFluxVectors .............................................................................................................. 481
23.21. Selection for Thermal Chokepoint .................................................................................................... 482
23.22. Geometry Settings for Chokepoint .................................................................................................. 483
23.23. Display of Chokepoint ..................................................................................................................... 484
23.24. Geometry Settings for StreamlinesFan ............................................................................................. 485
23.25. Color Settings for StreamlinesFans ................................................................................................... 485
23.26. Symbol Settings for StreamlinesFan ................................................................................................. 486
23.27. Display of StreamlinesFan ................................................................................................................ 487
23.28. Keyframe Animation Panel .............................................................................................................. 488
23.29. View From +Y .................................................................................................................................. 489
23.30. Animation Options Panel ................................................................................................................. 490
23.31. Details for PlaneCut ......................................................................................................................... 491
23.32. Details for TemperatureContours ..................................................................................................... 492
23.33. Display of PlaneCut ......................................................................................................................... 493
23.34. Quick Animation Settings ................................................................................................................ 494
23.35. Details of IsoVolume ........................................................................................................................ 495
23.36. Display of IsoVolume ....................................................................................................................... 496
23.37. Details for Line ForChart .................................................................................................................. 496
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23.38. Plot of TemperatureVariation Along ForChart ................................................................................... 497

23.39. Expression for VelocityRatio ............................................................................................................. 499
23.40. Creation of New Results Component ............................................................................................... 502
23.41. The Load Results Panel .................................................................................................................... 503
23.42. Display of BoardAndComponents .................................................................................................... 504
23.43. Display of Legend View ................................................................................................................... 505
23.44. Display of Streamlines Comparison .................................................................................................. 506
24.1. Geometry of the Datacenter Model ................................................................................................... 510
24.2. Expected Airflow Path ....................................................................................................................... 510
24.3. The Preferences Panel - Object types ................................................................................................. 512
24.4. The Create CRAC Panel ...................................................................................................................... 514
24.5.The CRAC Unit in the Graphics Window .............................................................................................. 515
24.6. Per-object Meshing Parameters for the Fans ...................................................................................... 516
24.7. The Copy Group CRACs Panel ............................................................................................................ 517
24.8. Two CRAC Units in the Graphics Window ........................................................................................... 518
24.9. The Create Rack (Front to Rear) Panel ................................................................................................. 519
24.10. Row of Server Racks in the Graphics Window ................................................................................... 520
24.11. The Copy Group RACKs Panel .......................................................................................................... 522
24.12. Two Rows of Server Racks in the Graphics Window ........................................................................... 523
24.13. The Create Rack (Front to Rear) Panel ............................................................................................... 524
24.14. Two Rows of High Density Server Racks in the Graphics Window ...................................................... 525
24.15. The Create Tile Panel ....................................................................................................................... 526
24.16. Row of Tiles in the Graphics Window ................................................................................................ 527
24.17. Per-object Meshing Parameters for the Tiles ..................................................................................... 528
24.18. Four Rows of Tiles in the Graphics Window ....................................................................................... 529
24.19. Two Rows of Return Grilles in the Graphics Window ......................................................................... 531
24.20. Two CRAC Return Grilles in the Graphics Window ............................................................................. 532
24.21. Per-object Meshing Parameters for the Return Grilles ....................................................................... 533
24.22. The Create PDU Panel ...................................................................................................................... 534
24.23. Two PDUs in the Graphics Window .................................................................................................. 535
24.24. The Completed Model ..................................................................................................................... 538
24.25. Mesh Control Panel ......................................................................................................................... 539
24.26. Creating Monitor Points .................................................................................................................. 540
24.28. Temperature Point Monitors ............................................................................................................ 544
24.29. Object Face Temperature Contours .................................................................................................. 546
24.30. Plane Cut Temperature Contours ..................................................................................................... 547
24.31. Isosurface of 90°F ............................................................................................................................ 548
24.32. Particle Traces ................................................................................................................................. 550
25.1. Comparison of the Geometry in Ansys DesignModeler and Ansys Icepak ............................................ 554
25.2. Creating a Geometry Component Module ......................................................................................... 555
25.3. Imported Model ................................................................................................................................ 556
25.4. Options Panel ................................................................................................................................... 557
25.5. Bodies Recognized as Ansys Icepak Objects ....................................................................................... 558
25.6. Bodies not Recognized as Ansys Icepak Objects ................................................................................. 559
25.7. FinsSlice1 Face Selection ................................................................................................................... 560
25.8. Details View of FinsSlice1 ................................................................................................................... 560
25.9. FinsSlice2 Bodies Selection ................................................................................................................ 561
25.10. Selecting a Row of Fins .................................................................................................................... 562
25.11. FanOpenings Face Selection ............................................................................................................ 564
25.12. BackOpenings Face Selection .......................................................................................................... 564
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25.13. Hub/Casing Faces Selection ............................................................................................................. 565

25.14. HousingFrontBack Bodies Selection ................................................................................................. 567
25.15. Selection of Housings, Fins, Panels, Openings, and Fans ..................................................................... 568
25.16. PWB, HS_AF0, and T0220_Case Bodies Selection .............................................................................. 569
25.17. Package Object Selection ................................................................................................................ 570
25.18. Coil Bodies Selection ....................................................................................................................... 571
25.19. Capacitors Bodies Selection ............................................................................................................. 572
25.20. BGAHS and Components Parts Selections ........................................................................................ 573
25.21. Final Model in Ansys DesignModeler ............................................................................................... 574
25.22. Final Tree Outline ............................................................................................................................ 575
25.23. Creating an Ansys Icepak Component Module ................................................................................. 576
25.24. Final Model ..................................................................................................................................... 577
26.1. Options Available for a New Icepak Session ........................................................................................ 579
26.2. File Selection Panel ........................................................................................................................... 580
26.3. Unpacked Model ............................................................................................................................... 581
26.4. Block Type ........................................................................................................................................ 582
26.5. Block Dimensions .............................................................................................................................. 583
26.6. Warning Message .............................................................................................................................. 584
26.7. Updated Cabinet Dimensions ............................................................................................................ 585
26.8. Updated Properties Tab for Cabinet ................................................................................................... 585
26.9. Select the Box Geometry ................................................................................................................... 586
26.10. Create an Assembly for the Box Geometry ....................................................................................... 587
26.11. Move the Fan to the Front-Panel-Fan Assembly ................................................................................ 588
26.12. Updated Model manager Window ................................................................................................... 589
26.13. Slack Settings and Max Element Size Inputs for assembly.1 ............................................................... 590
26.14. Fan Assembly Mesh Settings ............................................................................................................ 592
26.15. Mesh Parameters ............................................................................................................................. 593
26.16. Sorting the Model manager Window by Meshing Priority ................................................................. 594
26.17. Modifying the Meshing Priority ....................................................................................................... 594
26.18. Fan Curve and Swirl Inputs for the Fan Object .................................................................................. 596
26.19. Basic parameters/General setup ...................................................................................................... 597
26.20. DO Radiation Settings ..................................................................................................................... 598
26.21. Basic parameters/Defaults ............................................................................................................... 598
26.22. Basic parameters/Transient Setup .................................................................................................... 599
26.23. Solar load model parameters Panel .................................................................................................. 600
26.24. Creating a Point Monitor (Temperature) for the BGA Block - Method 1 .............................................. 601
26.25. Creating a Point Monitor (Temperature) for the BGA Block - Method 2 .............................................. 602
26.26. Point Monitors (Temperature and Velocity) for the Openings Rear_Panel_18 and Rear_Panel_4 ........ 602
26.27. Run Solution ................................................................................................................................... 603
26.28. Convergence and Point Monitor Plots .............................................................................................. 604
26.29. Selection for Postprocessing ............................................................................................................ 605
26.30. Display Contours of Temperature on Selected Objects ...................................................................... 606
26.31. Contours of Temperature on Selected Objects ................................................................................. 607
26.32. Plane cut Panel Settings for cut.1 ..................................................................................................... 608
26.33. Plane Cut of Temperature Contours within Avionics Box ................................................................... 608
26.34. Updated Point and Normal Settings for cut.1 ................................................................................... 609
26.35. Updated Plane Cut of Velocity Vectors .............................................................................................. 610
26.36. Updated Settings for face.2 ............................................................................................................. 611
26.37. Updated Graphical Display .............................................................................................................. 612
26.38. Updated Graphical Display .............................................................................................................. 613
26.39. Updated Fan Setup for Failure Mode ................................................................................................ 614
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26.40. Basic parameters and Transient parameters Panel Inputs .................................................................. 615
26.41. Time Dependant Variation for Ambient Temperature ........................................................................ 616
26.42. Use of Steady State Simulation as the Starting Point for the Transient Simulation .............................. 617
26.43. Post/Transient Settings .................................................................................................................... 618
27.1. SpaceClaim Open Dialog ................................................................................................................... 620
27.2. Initial Geometry in SpaceClaim .......................................................................................................... 620
27.3. SpaceClaim Edit Toolbar - Select Mode .............................................................................................. 621
27.4. Housing Face Selection ..................................................................................................................... 621
27.5. Split Body Button .............................................................................................................................. 621
27.6. Splitting the Housing and Side Fins ................................................................................................... 622
27.7. Randomize Body Colors .................................................................................................................... 623
27.8. Randomized Body Colors .................................................................................................................. 624
27.9. Splitting the Central Housing ............................................................................................................ 624
27.10. All Bodies ........................................................................................................................................ 625
27.11. Identify Objects ............................................................................................................................... 625
27.12. Convert to Icepak Primitives ............................................................................................................ 626
27.13. Icepak Icons in Structure Tree .......................................................................................................... 626
27.14. Non-Icepak Bodies .......................................................................................................................... 626
27.15. Simplify the PCB and TO Packages ................................................................................................... 627
27.16. Simplified PCB and TO Packages - Level 0 Simplification ................................................................... 628
27.17. Simplified PCB and TO Packages ...................................................................................................... 629
27.18. Remaining Non-Icepak Bodies ......................................................................................................... 630
27.19. Transformer .................................................................................................................................... 630
27.20. Simplified Transformer - Level 2 Simplification ................................................................................. 631
27.21. Simplified Core Body ....................................................................................................................... 632
27.22. Simplified Core Body - Level 1 Simplification .................................................................................... 632
27.23. Split the Core Body .......................................................................................................................... 633
27.24. Simplified Split Core Body - Level 1 Simplification ............................................................................ 633
27.25. Chassis and Fans ............................................................................................................................. 634
27.26. Chassis Face .................................................................................................................................... 635
27.27. Opening Tool .................................................................................................................................. 635
27.28. Simplified Chassis Side .................................................................................................................... 635
27.29. Front Panel ...................................................................................................................................... 636
27.30. Create Front Panel Faces .................................................................................................................. 636
27.31. Select Front Panel Faces .................................................................................................................. 636
27.32. Enable No Merge ............................................................................................................................. 637
27.33. Select Pull Option - Up To ................................................................................................................ 637
27.34. Select Chassis Face .......................................................................................................................... 637
27.35. Simplify the Fluid Cutouts ............................................................................................................... 638
27.36. Non-Icepak Bodies .......................................................................................................................... 638
27.37. Fan Body ......................................................................................................................................... 639
27.38. Simplified Fan - Level 3 Simplification .............................................................................................. 639
27.39. Fan Specifications ........................................................................................................................... 640
27.40. Final Converted Model .................................................................................................................... 640
27.41. Workbench - Transfer Data to Icepak ................................................................................................ 641
27.42. Workbench - Linked Icepak Module ................................................................................................. 641
27.43. Model in Icepak ............................................................................................................................... 642
27.44. Edit Icepak Length Unit ................................................................................................................... 643
27.45. Edit Fan Object Geometry ............................................................................................................... 644
27.46. Delete the CAD Fan ......................................................................................................................... 645
27.47. Set Fluid Cutout Block Type ............................................................................................................. 646
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27.48. Mesh Warnings ............................................................................................................................... 646

27.49. Adjust Front-Panel Mesh Priority ...................................................................................................... 647
27.50. Adjust Coil2 Mesh Priority ................................................................................................................ 647
27.51. Front-Panel Mesh with Fluid Cutouts ............................................................................................... 647
28.1. Customized Heat Sink with all Detailed Features ................................................................................ 650
28.2. Defeatured customized heat sink ...................................................................................................... 651
28.3. Create the Geometry Component ...................................................................................................... 651
28.4. Rename the Geometry Component ................................................................................................... 652
28.5. Create the Icepak Component ........................................................................................................... 652
28.6. Updated Project Schematic ............................................................................................................... 653
28.7. Import Operation .............................................................................................................................. 654
28.8. Project Schematic – Updated Cell Status ............................................................................................ 654
28.9. Accessing DesignModeler Electronics ................................................................................................ 656
28.10. Tree Outline .................................................................................................................................... 657
28.11. Simplification Type: Level 0 .............................................................................................................. 658
28.12. Updated Project Schematic ............................................................................................................. 658
28.13. Icepak Interface for Icepak-Simplify-Level0 ...................................................................................... 659
28.15. Heat sink ......................................................................................................................................... 660
28.16. Selection of Slice Surface ................................................................................................................. 661
28.17. Details View for Slice Operation ....................................................................................................... 661
28.18. Updated Tree Outline and Graphics Window .................................................................................... 661
28.19. Show Ice Bodies, Updated Tree Outline and Graphics Window .......................................................... 662
28.20. Show CAD Bodies, Updated Tree Outline and Graphics Window ........................................................ 662
28.21. Revert View and Context Menus ...................................................................................................... 663
28.22. Rename the Bodies After the Slice Operation ................................................................................... 663
28.23. Updated Tree Outline and Graphics window .................................................................................... 664
28.25. Icepak interface for Icepak-Simplify-Level1 ...................................................................................... 666
28.27. Updated Tree Outline ...................................................................................................................... 668
28.28. Updated Tree Outline and Details View for L3_Simplify3 ................................................................... 669
29.1. SpaceClaim Open Dialog ................................................................................................................... 674
29.2. Initial Geometry in SpaceClaim .......................................................................................................... 674
29.3. Icepak Simplify .................................................................................................................................. 675
29.4. Simplification Options -Level 0 .......................................................................................................... 675
29.5. Simplification Type: Level 0 ................................................................................................................ 675
29.6. Simplification Type: Level 0 ................................................................................................................ 676
29.8. Icepak Interface for Icepak-Simplify-Level0 ........................................................................................ 677
29.10. Heat sink ......................................................................................................................................... 678
29.11. Selection of Surface ......................................................................................................................... 679
29.12. Convert to Icepak Primitives ............................................................................................................ 679
29.13. Show Icepak Bodies, Updated Structure Tree, and Graphics Window ................................................. 680
29.14. Show Icepak Bodies, Updated Structure Tree, and Graphics Window ................................................. 680
29.15. Level 1 Simplification - New Component .......................................................................................... 681
29.17. Icepak interface for Icepak-Simplify-Level1 ...................................................................................... 683
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29.19. Simplification Options -Level 3 ........................................................................................................ 685
29.20. Updated Project Schematic and Facets Preview ................................................................................ 685
30.1. Electronics Box Model ....................................................................................................................... 690
30.2. Turning On Beta Options ................................................................................................................... 691
30.3. Create the Geometry Component ...................................................................................................... 692
30.5. Sample Layout for DM Shortcuts Toolbar ........................................................................................... 693
30.6. Updated Tree Outline and Graphics Window ...................................................................................... 694
30.7. Tree Outline ..................................................................................................................................... 695
30.8. DM Bodies Compatible with Icepak Native Geometry ......................................................................... 696
30.9. Repair and Analysis Tools Utilities in DM ............................................................................................ 697
30.10. Create and Suppress Fasteners, Updated Graphical Display .............................................................. 698
30.11. Collapsed and Expanded Views for Newly Created Parts ................................................................... 699
30.12. Show Ice Bodies in DM (left) and Model with Same Objects in Icepak (right) ..................................... 700
30.13. Show CAD Bodies – Updated Graphics Display for DM ...................................................................... 700
30.14. Examples of Complex Shapes from Tutorial Geometry - Sheet Metal Heat Sink for QFP1 Package and
Flow Guide for Fan System ........................................................................................................................ 701
30.15. Updated Tree Outline/Parts, Bodies View .......................................................................................... 701
30.16. Retain Only the Chassis Geometry in the Graphics Display Window .................................................. 702
30.17. Opening Operation for Chassis – Selection of Candidate Faces ........................................................ 702
30.18. Newly Created Parts and Surface Body ............................................................................................. 703
30.19. Updated Tree Outline/Parts, Bodies View .......................................................................................... 703
30.20. Selecting Chassis Cover and Housing ............................................................................................... 704
30.21. Updated Graphical Display in DM .................................................................................................... 704
30.22. Suppressing All Parts Other Than Chassis and Updated Tree Outline View ........................................ 705
30.23. Replace the Existing Icepak Model ................................................................................................... 705
30.24. Updated Icepak Graphics Display ..................................................................................................... 706
30.25. Delete Link Between MCAD and CFD Modules ................................................................................. 706
30.26. Updated WB Project Schematic ........................................................................................................ 707
30.27. Unsuppress Motherboard Part and Updated Graphics Display .......................................................... 707
30.28. Set Select Mode to Box Select .......................................................................................................... 708
30.29. Use Box Select to Select All the Geometry From the Motherboard Part ............................................. 708
30.30. Simplified Representation of Motherboard Part Geometry ............................................................... 709
30.33. Updated Graphics Display in DM ..................................................................................................... 711
30.34. Updated Tree Outline Listing and Simplified Representation for QFP-1 Part ...................................... 712
30.37. Updated Tree Outline View and Graphics Display in DM (Iso and +Z views) ....................................... 714
30.38. CPU_Socket Body ............................................................................................................................ 714
30.39. CPU_Socket Body – Select Cavity Faces ............................................................................................ 715
30.40. Details View for Fill Operation .......................................................................................................... 715
30.41. Body Representing Cavity in CPU_SOCKET ....................................................................................... 716
30.42. Updated Tree Outline Node — CPU-Box ........................................................................................... 716
30.43. Updated Graphics Display ............................................................................................................... 716
30.44. Use of Analysis Tools to Find Out TIM Thickness ................................................................................ 717
30.45. Creation of Surface Body for TIM ...................................................................................................... 718
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30.46. Updated Tree Outline View .............................................................................................................. 718

30.47. Use of Solid Extension ..................................................................................................................... 719
30.48. Before and After Use of Solid Extension ........................................................................................... 719
30.49. Level 1 Simplification for CPU-Box Part ............................................................................................ 720
30.50. Merge Newly Created Parts into CPU-Box Part, Updated Tree Outline View ........................................ 720
30.53. Updated Tree Outline View and Graphics Display in DM (Iso view) .................................................... 723
30.54. Electronics/Fan – Selection of Body to Extract Fan Data .................................................................... 723
30.55. Electronics/Fan – Selection of Hub/Casing Faces .............................................................................. 724
30.56. Updated Graphics Display in DM (Iso view) ...................................................................................... 724
30.57. Inner Face of the Top Side of the FLOW_GUIDE Body, Electronics/Opening ........................................ 725
30.59. FLOW_GUIDE – Selection of Outer Edges for Inner Face of Top Side .................................................. 726
30.60. FLOW_GUIDE – New Surface Body Created Using ‘Surfaces from Edges’ ............................................ 727
30.62. Inner Faces of Non-Uniform Sides of FLOW_GUIDE Body .................................................................. 728
30.63. Newly Created Surface Body – Flow_Guide_Non-Uniform-Face ........................................................ 728
30.64. FLOW_GUIDE Base Sides – Newly Created Surface Bodies ................................................................. 729
30.65. Updated Tree Outline and Graphics Display ..................................................................................... 730
30.68. Updated Tree Outline View and Graphics Display in DM (Iso and +Z views) ....................................... 733
30.69. Updated Tree Outline View ............................................................................................................. 733
30.70. Level 1 Simplification of DIMM, DIMM_SOCKET Bodies ..................................................................... 734
30.71. Updated Tree Outline View ............................................................................................................. 734
30.73. Selection of Inner Faces for DIMM_TIM Bodies ................................................................................. 736
30.75. Updated Graphics Display and Zoom-in +Z View .............................................................................. 738
30.76. Recreating the Heatsink Geometry .................................................................................................. 739
30.79. Updated DM Tree Outline, DM Graphics Display, Icepak Graphics Display .......................................... 742
31.1. A 3D Icepak Fan Object Assembly ..................................................................................................... 744
31.2. Unpacked Model Geometry .............................................................................................................. 745
31.3. Fluid Blocks Surrounding Fan Blade Geometry ................................................................................... 747
31.4. Updated Model Tree View ................................................................................................................. 747
31.5. MRF Settings ..................................................................................................................................... 748
31.6. Global Mesh Settings ........................................................................................................................ 749
31.7. Non-conformal Mesh Settings for FANS_CAD.1 Assembly ................................................................... 751
31.8.“Edit Levels” Settings for FANS_CAD.1 Assembly ................................................................................. 752
31.9. Surface Mesh of Fan Rotors ............................................................................................................... 753
31.10. Mesh Display - Cut Plane Through Rotor Center ............................................................................... 753
31.11. Modify Choice for Turbulence Model ............................................................................................... 754
31.12. Basic Solution Settings .................................................................................................................... 755
31.13. Easy Method to Snap Point Monitors to the Mesh Display ................................................................. 756
31.14. Residuals Plot .................................................................................................................................. 757
31.15. Temperature Monitors ..................................................................................................................... 758
31.16. Velocity Monitors ............................................................................................................................ 758
31.17. Surface Temperature Contours ........................................................................................................ 759
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31.18. Contour of Speed at Center of Z with MRF ........................................................................................ 759

31.19. Contour of Speed at Center of Z with Icepak 3D Fan Object .............................................................. 760
32.1. Total Power ....................................................................................................................................... 763
32.2. Object Geometry Edit Panel for heat_sink_minx ................................................................................ 764
32.3. Object Properties Edit Panel for heat_sink_minx ............................................................................... 765
32.4. Object Geometry Edit Panel for heat_sink_maxx ............................................................................... 766
32.5. Object Properties Edit Panel for heat_sink_maxx ............................................................................... 767
32.6. Heat Sink Assembly Slack Values ........................................................................................................ 768
32.7. Default Fluid ..................................................................................................................................... 769
32.8. The Advanced Tab of the Basic parameters Panel ............................................................................ 770
32.9. Assigning Variable for Altitude ........................................................................................................... 771
32.10. Assigning Parameters for Inlet Temperature ..................................................................................... 772
32.11. Primary Functions ........................................................................................................................... 773
32.12. Parametric Trials .............................................................................................................................. 774
32.13. Particle Traces ................................................................................................................................. 774
32.14.Temperature Contours on heat_sink_minx and heat_sink_maxx ....................................................... 775
33.1. Assign Material for Stock Object ........................................................................................................ 779
33.2. Select Definition Panel ...................................................................................................................... 780
33.3. Edit Thermal Modifier ........................................................................................................................ 782
33.4. Temperature of Objects Panel ............................................................................................................ 783
33.5. Maxwell 3D system ........................................................................................................................... 784
33.6. Suppress Bodies ................................................................................................................................ 789
33.7. Simplify1 – Coil Object ...................................................................................................................... 790
33.8. Simplify2 – Stock Object .................................................................................................................... 791
33.9. Imported Geometry in Icepak ............................................................................................................ 792
33.10. Resize Cabinet ................................................................................................................................. 793
33.11. Cabinet Properties .......................................................................................................................... 793
33.12. Coil Material .................................................................................................................................... 794
33.13. Mesh control Panel ........................................................................................................................ 795
33.14. Volumetric heat losses ..................................................................................................................... 798
33.15. Define summary report Panel .......................................................................................................... 799
33.16. Report summary data Panel ............................................................................................................ 800
35.1. SIwave Workflow Wizard Button ........................................................................................................ 824
35.2. SIwave Workflow Wizard .................................................................................................................... 824
35.3. Layer Stack-up Editor ........................................................................................................................ 825
35.4. Padstack Editor ................................................................................................................................. 826
35.5. Circuit Element Properties Panel ........................................................................................................ 827
35.6. Circuit Element Properties Panel ........................................................................................................ 827
35.7. Power/Ground Net Classification Panel .............................................................................................. 828
35.8. DC IR Configuration Panel ................................................................................................................. 829
35.9. Current and Voltage Sources ............................................................................................................. 829
35.10. Launch Validation Check Panel ........................................................................................................ 830
35.11. Validation Check Results Panel ......................................................................................................... 831
35.12. DC IR Configuration Panel ............................................................................................................... 832
35.13. Compute DC Current and Voltage Distribution ................................................................................. 832
35.14. SIwave Options Panel - DC Tab ......................................................................................................... 833
35.15. SIwave Options Panel - DC Advanced Tab ......................................................................................... 834
35.16. SIwave Options Panel - Multiprocessing Tab ..................................................................................... 835
35.17. Compute DC Current and Voltage Distribution ................................................................................. 836
35.18. Process Monitor and Information/Errors/Warnings Panels ................................................................ 837
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35.19. Export ANF File in Generic Format ................................................................................................... 837

35.20. SIwave Simulation Tab ..................................................................................................................... 838
35.21. Icepak Simulation Setup Dialog Box - Simulation Setup Tab .............................................................. 838
35.22. Icepak Simulation Setup Dialog Box - Thermal Environment Tab ....................................................... 840
35.23. Process Monitor .............................................................................................................................. 841
35.24. Results Pane .................................................................................................................................... 841
35.25. Temperature Contours ..................................................................................................................... 842
35.26. Icepak Simulation Setup Dialog Box - Simulation Setup Tab .............................................................. 843
35.27. Icepak Simulation Setup Dialog Box - Thermal Environment Tab ....................................................... 844
35.28. Icepak Simulation Setup Dialog Box - Component Configuration Tab ................................................ 845
35.29. Icepak Simulation Setup Dialog Box - Icepak Cabinet Size Tab .......................................................... 846
35.30. Results Pane .................................................................................................................................... 846
35.31. Temperature Contours - Forced Convection ..................................................................................... 847
35.32. SIwave Export Tab ........................................................................................................................... 848
35.33. Icepak Export Dialog Box - Simulation Setup Tab .............................................................................. 849
35.34. Icepak Export Dialog Box - Thermal Environment Tab ....................................................................... 850
35.35. Components To Include and Modify ................................................................................................ 850
35.36. Icepak Export Dialog Box - Icepak Cabinet Size Tab ........................................................................... 851
35.37. Model in the Icepak Graphics Window ............................................................................................. 852
35.38. Basic Parameters Panel .................................................................................................................... 853
35.39. Cabinet Panel - Geometry Tab .......................................................................................................... 854
35.40. Cabinet Panel - Properties Tab ......................................................................................................... 854
35.41. Grille Panel - Properties Tab ............................................................................................................. 855
35.42. Printed Circuit Boards Panel - Properties Tab .................................................................................... 856
35.43. Powermap Locations and Information ............................................................................................. 857
35.44. Fan Panel - Geometry Tab ................................................................................................................ 858
35.45. Fan Panel - Properties Tab ................................................................................................................ 859
35.46. Copy Fan Panel ................................................................................................................................ 860
35.47. Assemblies Panel - Meshing Tab ....................................................................................................... 861
35.48. Mesh Control Panel - Display Tab ..................................................................................................... 862
35.49. Model Mesh .................................................................................................................................... 863
35.50. SIwave-Icepak Coupling Iterator for Single and Multiple PCBs Panel ................................................. 863
35.51. Instructions Panel ............................................................................................................................ 864
35.52. Project Tree - Object Selection for Object Face ................................................................................. 864
35.53. Object Face and Object Face Contours Panels .................................................................................. 865
35.54. Object Face - Temperature Contours ................................................................................................ 866
35.55. Object Face and Object Face Particles Panels ................................................................................... 867
35.56. Object Face - Speed Particle Traces .................................................................................................. 867
35.57. Copy Fan Panel ................................................................................................................................ 869
35.58. SIwave-Icepak Coupling Iterator for Single and Multiple PCBs Panel ................................................. 870
35.59. Object Face - Temperature Contours ................................................................................................ 871
35.60. Object Face and Object Face Particles Panels ................................................................................... 871
36.1. TEC in Ansys Icepak ........................................................................................................................... 874
36.2. IC Package on PCB ............................................................................................................................ 875
36.3. Package Object - Dimensions Tab ...................................................................................................... 876
36.4. Package Object - Die/Mold Tab .......................................................................................................... 877
36.5. HeatSpreader1 - Geometry Tab .......................................................................................................... 878
36.6. Model with Heatspreader1 Added ..................................................................................................... 879
36.7. TECs Library ...................................................................................................................................... 879
36.8. Move the TEC .................................................................................................................................... 880
36.9. Model with TEC Added ...................................................................................................................... 880
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36.10. HeatSpreader2 - Geometry Tab ........................................................................................................ 881

36.11. Model with Heatspreader2 Added ................................................................................................... 882
36.12. LowerWallBoundary - Geometry Tab ................................................................................................ 883
36.13. LowerWallBoundary - Property Tab .................................................................................................. 884
36.14. UpperColdPlateWallBoundary - Geometry Tab ................................................................................. 885
36.15. UpperColdPlateWallBoundary - Property Tab ................................................................................... 886
36.16. Autoscaled Cabinet ......................................................................................................................... 886
36.17. TECs Assembly - Meshing Tab .......................................................................................................... 888
36.18. Package Assembly - Meshing Tab ..................................................................................................... 889
36.19. Model Manager ............................................................................................................................... 890
36.20. Mesh Control Panel ......................................................................................................................... 891
36.21. Monitor Points Folder ...................................................................................................................... 892
36.22. Basic Parameters Panel .................................................................................................................... 893
36.23. Run TEC Macro ................................................................................................................................ 894
36.24. Run TEC Panel ................................................................................................................................. 895
36.26. Temperature Monitor Point Plot ....................................................................................................... 897
36.27. Plane Cut Panel ............................................................................................................................... 898
36.28. Plane Cut ........................................................................................................................................ 898
36.29. Define Summary Report Panel ......................................................................................................... 899
36.30. Summary Report ............................................................................................................................. 899
37.1. Welcome to Icepak ............................................................................................................................ 902
37.2. File Selection Dialog .......................................................................................................................... 903
37.3. Location for the Unpacked Project Dialog .......................................................................................... 904
37.4. Parameters and Optimization panel ................................................................................................... 905
37.5. State-space Inputs ............................................................................................................................ 906
37.6. State-space Outputs .......................................................................................................................... 907
37.7. Enter a Solution ID and Run the Solution ........................................................................................... 908
37.8. Steady State Solution Residuals ......................................................................................................... 909
37.9. Set Up Transient Trials ....................................................................................................................... 910
37.10. Transient Trials Residuals ................................................................................................................. 911
37.11. Thermal Model Identification ........................................................................................................... 912
37.12. Thermal Model Identification Dialog ................................................................................................ 913
37.13. Browse for Folder Dialog ................................................................................................................. 914
37.14. ROM Creation Message ................................................................................................................... 914
37.15. Thermal ROM SML Component ........................................................................................................ 915
37.16. Thermal ROM SML in the Workspace ................................................................................................ 915
37.17. Output Dialog ................................................................................................................................. 916
37.18. ROM Schematic ............................................................................................................................... 917
37.19. CONST1 Parameters Dialog .............................................................................................................. 918
37.20. TRAPEZ1 Parameters Dialog ............................................................................................................ 919
37.21. Create a Rectangular Plot Report ..................................................................................................... 920
37.22. Report Dialog .................................................................................................................................. 920
37.23. Transient Analysis Setup Dialog ....................................................................................................... 921
37.24. Analyze the ROM ............................................................................................................................. 922
37.25. XY Plot with Temperature Results .................................................................................................... 923
38.1. Options Available for a New Icepak Session ........................................................................................ 926
38.2. File Selection Panel ........................................................................................................................... 927
38.3. Unpacked Model ............................................................................................................................... 928
38.4. Preferences Panel .............................................................................................................................. 929
38.5. Custom Materials .............................................................................................................................. 930
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38.6. Materials Panel (BT) ........................................................................................................................... 930

38.7. Materials Panel (Quantum QMI 301) ................................................................................................... 931
38.8. Materials Panel (64SN 37PB) .............................................................................................................. 932
38.9. Package Panel (Dimensions Tab) ........................................................................................................ 933
38.10. Package Panel (Substrate Tab) ......................................................................................................... 934
38.11. Package Panel (Solder and Die/Mold Tabs) ....................................................................................... 935
38.12. Traces ............................................................................................................................................. 936
38.13. Show Metal Fractions Panel ............................................................................................................. 936
38.14. Metal Fractions (M1 TOP) ................................................................................................................. 937
38.15. Import CTM Profile Files Panel ......................................................................................................... 938
38.16. Powermap Info Panel ...................................................................................................................... 939
38.17. Powermap ...................................................................................................................................... 940
38.18. Powermap ...................................................................................................................................... 941
38.19. Packages Panel - Dimensions Tab ..................................................................................................... 942
38.20. Align Face Centers ........................................................................................................................... 943
38.21. Assemblies Panel - Meshing Tab (fccsp-assembly) ............................................................................ 944
38.22. Assemblies Panel - Meshing Tab (fccsp-powermap) .......................................................................... 945
38.23. Updated Model Tree ........................................................................................................................ 946
38.24. Per-object Mesh Settings ................................................................................................................. 947
38.25. Mesh Cut Plane ............................................................................................................................... 948
38.26. Solve Panel ..................................................................................................................................... 949
38.27. Solution Residuals Panel .................................................................................................................. 950
38.28. Monitor Panels ................................................................................................................................ 951
38.29. Object Face Panel ............................................................................................................................ 952
38.30. Object Face Contours Panel ............................................................................................................. 953
38.31. Powermap Temperature Contours ................................................................................................... 953
38.32. Define Summary Report Panel ......................................................................................................... 954
38.33. Report Summary data Panel ............................................................................................................ 954
38.34. Object Face (Facet) Panel ................................................................................................................. 955
38.35. Heat Transfer Coefficient Contours ................................................................................................... 956
38.36. Heat Transfer Coefficient Contours and Cut Plane of Velocity Vectors ................................................ 956
38.37. RedHawk Back Annotations Panel .................................................................................................... 957
38.38. RedHawk Back Annotations Panel .................................................................................................... 958
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List of Tables
3.1. Slack Values for the Amplifier and Fan .................................................................................................... 73
4.1. Values for the Curve Specification Panel ............................................................................................... 106
4.2. Heatsink Properties ............................................................................................................................. 117
4.3. Slack Values for Heatsink-packages-asy Assembly ................................................................................ 119
4.4. Slack Values for Fan-asy Assembly ....................................................................................................... 120
5.1. Cabinet Start and End Values ............................................................................................................... 136
5.2. Specifications of block.1 and block.2 ................................................................................................... 137
5.3. Cylindrical Block Specifications ............................................................................................................ 138
5.4. Plate Specifications ............................................................................................................................. 139
5.5. Opening Specifications ....................................................................................................................... 139
5.6. Openings at Cabinet Boundary Specifications ...................................................................................... 140
5.7. Object Face and Plane Cut Specifications ............................................................................................. 147
6.1. Orthotropic Properties ........................................................................................................................ 154
6.2. Block Specifications ............................................................................................................................ 155
6.3. Base and Pin Specifications ................................................................................................................. 155
6.4. Slack Values for Heatsink-asy ............................................................................................................... 159
6.5. Slack Values for Vent-asy ...................................................................................................................... 159
6.6. Slack Values for Fan-asy ....................................................................................................................... 159
6.7. Slack Values for HS-vent-fan-asy .......................................................................................................... 160
6.8. Object face and Plane cut Specifications .............................................................................................. 164
12.1. Maximum Source Temperature for Different Models .......................................................................... 286
13.1. Object Face and Plane Cut Specifications ........................................................................................... 298
16.1.Thickness Information on the Board (Layer 1: Top, Layer 7: Bottom layers) ............................................ 356
17.1.Thickness Information on the Board (Layer 1: Top, Layer 7: Bottom layers) ............................................ 370
18.1. Available Details for Objects in the Model .......................................................................................... 389
18.2. Available Information for 400 PBGA ................................................................................................... 390
21.1. Object Parameters ............................................................................................................................ 441
22.1. Object Properties .............................................................................................................................. 451
22.2. Coordinates for the Cabinet (Specify by: Start / end) ........................................................................... 452
22.3. Slack Values ...................................................................................................................................... 454
24.1. Size and Capacity of Heat Sources in Datacenter ................................................................................ 510
26.1. Slack Settings for the Remaining Assemblies ...................................................................................... 590
26.2. Material and Power Inputs ................................................................................................................. 595
28.1. Simplification Types in DM for CAD-to-Icepak Conversion .................................................................. 655
31.1. Fluid Block Settings for MRF Setup ..................................................................................................... 746
31.2. Location of Point Monitors ................................................................................................................ 756
32.1. Functions .......................................................................................................................................... 773
34.1. Cabinet Geometry ............................................................................................................................. 811
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Chapter 1: Using This Manual
1.1. What’s In This Manual
This manual contains tutorials that teach you how to use Ansys Icepak to solve different types of
problems. In each tutorial, features related to problem setup and postprocessing are demonstrated.
The tutorial Finned Heat Sink (p. 5) provides detailed instructions designed to introduce the beginner
to Ansys Icepak. This tutorial provides explicit instructions for all steps in the problem setup, solution,
and postprocessing. The remaining tutorials assume that you have read or solved the tutorial Finned
Heat Sink (p. 5), or that you are already familiar with Ansys Icepak and its interface. In these tutorials,
some steps will not be shown explicitly. The input files are available for download on the Ansys Help
site.
1.2. How To Use This Manual

Depending on your familiarity with computational fluid dynamics and Ansys Icepak, you can use this
tutorial guide in a variety of ways:
1.2.1. For the Beginner
1.2.2. For the Experienced User
1.2.1. For the Beginner

If you are a beginning user of Ansys Icepak, you should first read and solve the tutorial Finned Heat
Sink (p. 5), in order to familiarize yourself with the interface and with basic setup and solution pro-
cedures. You may then want to try a tutorial that demonstrates features that you are going to use in
your application. For example, if you are planning to solve a problem involving radiation, you should
look at the tutorial Radiation Modeling (p. 265).
You may want to refer to other tutorials for instructions on using specific features, such as grouping
objects, even if the problem solved in the tutorial is not of particular interest to you.
1.2.2. For the Experienced User

If you are an experienced Ansys Icepak user, you can read and/or solve the tutorial(s) that demonstrate
features that you are going to use in your application. For example, if you are planning to solve a
problem involving radiation, you should look at the tutorial Radiation Modeling (p. 265).
You may want to refer to other tutorials for instructions on using specific features, such as grouping
objects, even if the problem solved in the tutorial is not of particular interest to you.
of ANSYS, Inc. and its subsidiaries and affiliates. 1
Using This Manual
1.3. Typographical Conventions Used In This Manual

Several typographical conventions are used in this manual’s text to facilitate your learning process.
• Different type styles are used to indicate graphical user interface menu items and text inputs that
you enter (for example, Open project panel, enter the name projectname).
• A mini flow chart is used to indicate the menu selections that lead you to a specific panel. For example,
Model → Generate mesh
indicates that the Generate mesh option can be selected from the Model menu at the top of the
Ansys Icepak main window.
The arrow points from a specific menu toward the item you should select from that menu.
• A mini flow chart is also used to indicate the list tree selections that lead you to a specific panel or
operation. For example,
Problem setup → Basic parameters
indicates that the Basic parameters item can be selected from the Problem setup node in the
Model manager window
• Pictures of toolbar buttons are also used to indicate the button that will lead you to a specific panel.
For example, indicates that you will need to click on this button (in this case, to open the Walls
panel) in the toolbar.
1.4. Mouse Conventions Used In This Manual

The default mouse buttons used to manipulate your model in the graphics window are described in
Manipulating Graphics With the Mouse in the Icepak User’s Guide. Although you can change the mouse
controls in Ansys Icepak to suit your preferences, this manual assumes that you are using the default
settings for the mouse controls. If you change the default mouse controls, you will need to use the
mouse buttons you have specified instead of the mouse buttons that the manual tells you to use.
1.5. When To Call Your Ansys Icepak Support Engineer

The Ansys Icepak support engineers can help you to plan your modeling projects and to overcome any
difficulties you encounter while using Ansys Icepak. If you encounter difficulties we invite you to call
your support engineer for assistance. However, there are a few things that we encourage you to do
before calling:
1. Read the section(s) of the manual containing information on the options you are trying to use.
2. Recall the exact steps you were following that led up to and caused the problem.
3. Write down the exact error message that appeared, if any.
4. For particularly difficult problems, package up the project in which the problem occurred (see Un-
packing Model Files in the Icepak User’s Guide for instructions) and send it to your support engineer.
2 of ANSYS, Inc. and its subsidiaries and affiliates.
When To Call Your Ansys Icepak Support Engineer
This is the best source that we can use to reproduce the problem and thereby help to identify the
cause.
Chapter 2: Finned Heat Sink
2.1. Introduction
This tutorial demonstrates how to model a finned heat sink using Ansys Icepak as well as many features
and functions essential to any Ansys Icepak project. For the sake of brevity, many of the later tutorials
do not cover basic steps or explain the steps in detail as those tutorials assume you have completed
this tutorial beforehand.
In this tutorial you will learn how to:
• Create a new project.
• Create a model using blocks, openings, fans, sources, and plates.
• Generate a mesh for your model.
• Set up a simulation with various physical conditions and parameters, including turbulence.
• Calculate a solution.
• Post-process your results by using object faces, plane cuts, and isosurfaces to create contours and
vector fields.
Note:
Mesh counts and solution results may differ slightly due to enhancements to the
meshing algorithm and Fluent solver, respectively.
2.2. Prerequisites
This tutorial assumes that you have little to no experience with Ansys Icepak and thus each step is de-
scribed explicitly.
2.3. Problem Description

The cabinet contains an array of five high-power devices, a backing plate, ten fins, three fans, and a
free opening, as shown in Figure 2.1: Problem Specification (p. 6). The fins and backing plate are con-
structed of extruded aluminum. Each fan has a total volume flow rate of 18 cfm and each source dissipates
power at the rate of 33 W. According to the design objective, the base of the devices should not exceed
65°C when air sweeps the fins at an ambient temperature of 20°C.
Finned Heat Sink
Figure 2.1: Problem Specification
2.4. Step 1: Create a New Project

1. Start Ansys Icepak, as described in Starting Ansys Icepak.
When Ansys Icepak starts, the Welcome to Icepak panel opens automatically.
2. Click New in the Welcome to Icepak panel to start a new Ansys Icepak project.
The New project panel appears.
Step 2: Build the Model
3. Specify a name for your project and click Create.
Ansys Icepak creates a default cabinet with the dimensions 1 m 1m 1 m, and displays the
cabinet in the graphics window.
Note:
You can rotate the cabinet around a central point using the left mouse button, or you
can translate it to any point on the screen using the middle mouse button. You can zoom
into and out from the cabinet using the right mouse button. To restore the cabinet to
its default orientation, select Home position in the Orient menu. Alternatively, you can
click the Home position icon ( ) above the graphics display window or press the H
key.
2.5. Step 2: Build the Model

To build the model, you will first resize the cabinet to its proper size. Then you will create the backing
plate and opening, followed by the elements that will be duplicated (that is, the fans, fins, and devices).
1. Resize the default cabinet in the Cabinet panel.
Finned Heat Sink
Model Cabinet
Tip:
You can also open the Cabinet panel by selecting the Cabinet item in the Model manager
window and then clicking the Edit object button ( ) in the Object modification toolbar.
Resizing of the cabinet object can also be done in the geometry window in the lower
right hand corner of the GUI.
a. In the Cabinet panel, click the Geometry tab.
b. Under Location, enter the following coordinates:
xS 0 xE 0.075
yS 0 yE 0.25
zS 0 zE 0.356
c. Click Done to resize the cabinet and close the panel.
d. In the Orient menu, select Scale to fit to scale the view of the cabinet to fit the graphics window.
Extra:
You can also scale the view by clicking the Scale to fit button ( ).
Extra:
After selecting the object to be edited in the Model manager window, there are
several ways you can open the Edit panel:
• Double-click the object in the Model manager window, or
– Type Ctrl+E, or
– Right-click the object in the Model manager window and scroll to Edit object,
or
– Click the Edit button in the object geometry window located in the bottom right-
hand corner, or
– Click the Edit icon ( ) in the model toolbar.
2. Create the backing plate.
The backing plate is 0.006 m thick and divides the cabinet into two regions: the device side (where
the high-power devices are contained in a housing) and the fin side (where the fins dissipate heat
generated by the devices). The backing plate is represented in the model by a solid prism block.
Extra:
Blocks and conducting thick plates allow six-sided control for meshing and thermal spe-
cifications. Conducting thin plates, however, have no physical thickness and therefore
allow for only two-sided control.
a. Click the Create blocks button ( ) to create a new block.
Ansys Icepak creates a new solid prism block in the center of the cabinet. You need to change
the size of the block.
b. Click the Edit object button ( ) to open the Blocks panel.
c. Click the Geometry tab.
d. Enter the following coordinates for the block:
xS 0 xE 0.006
yS 0 yE 0.25
zS 0 zE 0.356
Finned Heat Sink
e. Click Done to modify the block and close the panel.
3. Create the free opening on the fin side of the backing plate.
a. Click the Create openings button ( ) to create a new opening.
Ansys Icepak creates a free rectangular opening on the X-Y plane at the center of the cabinet.
You need to change the size of the opening.
b. Click the Edit object button ( ) to open the Openings panel.
d. Enter the following coordinates for the opening:
xS 0.006 xE 0.075
yS 0 yE 0.25
zS 0.356 zE —
e. Click Done to modify the opening and close the panel.
4. Create the first fan.
Each fan is physically identical to the others, except with respect to its location on the cabinet wall.
To create the set of three fans, you will build a single fan as a template and then create two copies,
each with a specified offset in the y direction.
a. Click the Create fans button ( ) to create a new fan.
Ansys Icepak creates a free circular fan lying in the X-Y plane in the center of the cabinet. You
need to change the size of the fan and specify its volumetric flow rate.
b. Click the Edit object ( ) to open the Fans panel.
d. Enter the following coordinates for the fan:
xC 0.04
yC 0.0475
Finned Heat Sink
zC 0
e. Enter 0.03 for the external radius (Radius), and 0.01 for the internal radius (Int Radius).
f. Click the Properties tab.
g. Keep the default Fan type of Intake.
h. Under the Fan flow tab, select Fixed and Volumetric. Enter a volumetric flow rate of 18 cfm.
Note:
Make sure to update the units to cfm by clicking on the triangle button and selecting
cfm from the drop-down list.
i. Click Done to modify the fan and close the panel.
5. Copy the first fan (fan.1) to create the second and third fans (fan.1.1 and fan.1.2).
a. In the graphics display window, select fan.1 using the right mouse button.
b. In the object context menu, select Copy and the Copy fan fan.1 panel opens.
c. Enter 2 as the Number of copies.
d. Select the Translate option and specify a Y offset of 0.0775 m.
Finned Heat Sink
e. Click Apply.
Ansys Icepak makes two copies of the original fan, each offset by 0.0775 m in the y direction
from the previous one.
Extra::
Alternatively, you can simply select the object(s) you need to copy in the Model manager
window and then press Ctrl+C to bring up the Copy panel for the object(s).
6. Create the first high-power device.
Like the fans, each device is physically identical to the others, except with respect to its location in
the cabinet. To create the set of five devices, you will build a single rectangular planar source as a
template and then create four copies, each with a specified offset in the y direction.
a. Click the Create sources button ( ) to create a source.
Ansys Icepak creates a free rectangular source in the center of the cabinet. You need to change
the geometry and size of the source and specify its heat source parameters.
Note:
For planar objects, select the desired plane first, then enter the coordinates.
b. Click the Edit object button ( ) to open the Sources panel.
d. Keep the default selection of Rectangular.
e. In the Plane drop-down list, select Y-Z.
f. Enter the following coordinates for the source:
xS 0 xE —
yS 0.0315 yE 0.0385
zS 0.1805 zE 0.2005
g. Click the Properties tab.
Finned Heat Sink
h. Under Thermal specification, set the Total power to 33 W.
i. Click Done to modify the source and close the panel.
7. Copy the first device (source.1) to create the other four devices (source.1.1, source.1.2, source.1.3,
and source.1.4).
a. In the Model manager window, select the source.1 item under the Model node.
b. Click the Copy object button ( ).
c. Follow the same instructions that you used above to copy the fans, using a Y offset of 0.045 m
to create 4 copies.
8. Create the first fin.
Like the fans and devices, each fin is physically identical to the others, except with respect to its
location in the cabinet. To create the array of ten fins, you will build a single rectangular plate as a
template, and then create nine copies, each with a specified offset in the y direction.
a. Click the Create plates button ( ) to create a plate.
Ansys Icepak creates a free rectangular plate on the X-Y plane at the center of the cabinet. You
need to change the orientation and size of the plate and specify its thermal parameters.
b. Click the Edit object button ( ) to open the Plates panel.
d. In the Plane drop-down list, select X-Z.
e. Enter the following coordinates for the plate:
xS 0.006 xE 0.075
yS 0.0125 yE —
zS 0.05 zE 0.331
f. Click the Properties tab.
g. Under Thermal model, select Conducting thick from the drop-down menu.
h. Set the Thickness to 0.0025 m.
Finned Heat Sink
i. Keep default as the Solid material.
Note:
Since the default solid material is extruded aluminum, you do not need to explicitly
specify the material here.
j. Click Done to modify the plate and close the panel.
9. Copy the first fin (plate.1) to create the other nine fins (plate.1.1, plate.1.2, ..., plate.1.9).
a. In the Model manager window, select the plate.1 item under the Model node.
b. Click the Copy object button ( ).
c. Follow the same instructions that you used above to copy the fans, using a Y offset of 0.025 m
to create 9 copies.
The completed model is shown in Figure 2.2: Completed Model for the Finned Heat Sink (p. 19),
visible in the Isometric view (available in the Orient menu or by clicking the Isometric view button
( )).
Note:
You can remove the object names by clicking the Display object names button ( ).
Figure 2.2: Completed Model for the Finned Heat Sink
10. Display objects by type.
You can display all object types, filter blocks by type (fluid, solid, network, hollow), and display blocks
with traces and/or CAD block. This feature is useful for model verification. You can display all plate
objects that have the conducting thick sub type.
a. Model Show objects by type
b. The Show objects by type panel appears as shown in Figure 2.3: Show objects by type Pan-
el (p. 19).
Figure 2.3: Show objects by type Panel
Finned Heat Sink
c. Select Plate for Object type and Conducting thick for Sub type.
d. Click Display to show the conducting thick plates. The model then appears as in Figure 2.4: Display
of Conducting Thick Plate Objects (p. 20).
Figure 2.4: Display of Conducting Thick Plate Objects
e. Click Close to exit the Show objects by type panel.
11. Check the model to be sure that there are no problems (for example, objects that are too close to-
gether to allow for proper mesh generation).
Step 3: Generate a Mesh
Model Check model
Note:
You can also click the Check model button ( ) to check the model.
Note:
Ansys Icepak should report in the Message window that 0 problems were found.
12. Check the definition of the modeling objects to ensure that you specified them properly.
View Summary (HTML)
The summary report now appears in a web browser. The summary displays a list of all the objects
in the model and all the parameters that have been set for each object. You can view the detailed
version of the summary by clicking the appropriate object names or property specifications. If you
notice any incorrect specifications, you can return to the appropriate modeling object panel and
change the settings in the same way that you originally entered them.
Note:
The summary report also shows the user-specified material properties for each of the
objects to help identify the proper material specifications. Figure 2.5: Partial Table of
Summary Report for Blocks (p. 21) shows the summary report for block.1, which includes
its material specifications.
Figure 2.5: Partial Table of Summary Report for Blocks
2.6. Step 3: Generate a Mesh

You will generate the mesh in two steps. First you will create a coarse mesh and examine it to determine
where further mesh refinement is required. Then you will refine the mesh based on your observations
of the coarse mesh.
Extra:
For more information on how to refine a mesh locally, refer to Refining the Mesh Locally.
Finned Heat Sink
Model Generate mesh
Extra:
You can also generate a mesh by clicking the Generate mesh button ( ), which opens the
Mesh control panel.
1. Generate a coarse (minimum-count) mesh.
a. In the Mesh control panel, select Coarse in the Mesh parameters drop-down list.
Ansys Icepak updates the panel with the default meshing parameters for a coarse (minimum-
count) mesh, shown in the panel below.
b. Set the Mesh units and all the Minimum gap units to mm.
c. Set the Minimum gap to 1 mm for X, Y, and Z.
d. Set the Max X size to 3.5, the Max Y size to 12.5, and the Max Z size to 17.5.
e. Click the Generate button to generate the coarse mesh.
Finned Heat Sink
Note:
If the Allow minimum gap changes option is unchecked under the Misc tab, Ansys
Icepak will inform you that your minimum object separation is more than 10% of the
smallest size object in the model. You can stop the meshing process, ignore the
warning, or allow Ansys Icepak to correct the values.
f. If this warning appears, click Change value and mesh in the Minimum separation in x and
Minimum separation in y panels to accept the recommended changes to your model and
continue generating the mesh.
2. Examine the coarse mesh on a cross-section of the model.
a. Click the Display tab.
b. Select the Cut plane option.
c. In the Set position drop-down list, select X plane through center.
d. Select the Display mesh option.
The mesh display plane is perpendicular to the fins, and aligned with the devices, as shown in
Figure 2.6: Coarse Mesh on the Y-Z Plane (p. 26).
Note:
The number of elements may vary slightly on different machines.
Finned Heat Sink
Figure 2.6: Coarse Mesh on the Y-Z Plane
e. Use the slider bar to move the plane cut through the model. See Figure 2.7: Fine and Coarse
Mesh on the Y-Z Plane (p. 27) to examine a close-up view of the coarse mesh.
Note:
You can change the mesh color using the Surface mesh color and the Plane mesh
color options.
The mesh elements near the fins are too large to sufficiently resolve the problem physics. In the
next step, you will generate a finer mesh.
3. Generate a finer mesh.
a. Click the Settings tab.
b. Under the Global tab, select Normal in the Mesh parameters drop-down list.
Ansys Icepak updates the panel with the default meshing parameters under the Global tab.
4. Click the Generate button in the Mesh control panel to generate the finer mesh.
5. Examine the new mesh.
The graphics display updates automatically to show the new mesh. Click the Display tab and use
slider bar to advance the plane cut and view the mesh throughout the model.
Figure 2.7: Fine and Coarse Mesh on the Y-Z Plane
6. Turn off the mesh display.
a. Click the Display tab in the Mesh control panel.
b. Deselect the Display mesh option.
c. Click Close to close the Mesh control panel.
Note:
After deselecting the Display mesh option and closing the Mesh control panel, you
can display the mesh on selected objects by using the context menu in the graphics
display window. To display the context menu, hold down the Shift key and press the
right mouse button anywhere in the graphics window, but not on an object. Select
Display mesh and select the object you want it displayed on.
Finned Heat Sink
Figure 2.8: Display mesh Option
2.7. Step 4: Physical and Numerical Settings

Before starting the solver, first review estimates of the Reynolds and Peclet numbers to check that the
proper flow regime is being modeled.
1. Check the values of the Reynolds and Peclet numbers.
Solution settings Basic settings
Step 4: Physical and Numerical Settings
Figure 2.9: Basic settings panel
a. Click the Reset button as shown in Figure 2.9: Basic settings panel (p. 29). Reset calculates the
Reynolds and Peclet numbers.
b. Check the values printed to the Message window.
The Reynolds and Peclet numbers are approximately 13,000 and 9,000, respectively, so the flow
is turbulent. Ansys Icepak consequently recommends setting the flow regime to turbulent.
Note:
These values are only estimates, based on the current model setup. Actual values may
vary, and may need verification, depending on your design.
c. Change the Number of iterations to 200.
d. Click Accept to save the solver settings.
2. Using the Problem setup wizard, enable turbulence modeling using the zero equation turbulence
model and neglecting radiation heat transfer.
a. In the Model manager window, right-click Problem setup and then select Problem setup
wizard (Figure 2.10: Problem setup wizard panel at step 1 of 14 (p. 30)). The Problem setup
wizard provides a simple interface with user guidance for defining the physics of the model.
Finned Heat Sink
Figure 2.10: Problem setup wizard panel at step 1 of 14
b. For step 1 of 14, keep the default settings for check boxes. Click Next.
c. For step 2 of 14, keep the default flow condition selected. Click Next.
d. Note that you are now at step 5 of 14 according to the Problem setup wizard panel, shown in
Figure 2.11: Problem setup wizard at step 5 of 14 (p. 31). Ensure that you select Set flow regime
to turbulent.
Extra:
Hold your mouse pointer over any selection in the Problem setup wizard to have a
text bubble appear for additional information on the selection, as shown in Fig-
ure 2.11: Problem setup wizard at step 5 of 14 (p. 31).
Figure 2.11: Problem setup wizard at step 5 of 14
Click Next.
e. For step 6 of 14, select Zero equation (mixing length) as your turbulence model. Click Next.
f. For step 7 of 14, select Ignore heat transfer due to radiation. Click Next.
g. Note that you are now at step 9 of 14 according to the panel. Leave the check box empty to
exclude solar radiation and click Next.
h. For step 10 of 14, select Variables do not vary with time (steady-state) for steady-state simu-
lation. Click Next.
i. Note that you are now at step 14 of 14, as shown in Figure 2.12: Problem setup wizard at step
14 of 14 (p. 32). Ignore altitude effects by leaving the check boxes empty. Click Done to finish
the Problem setup wizard, fully defining the problem setup.
Finned Heat Sink
Note:
You can edit these settings and other aspects of the problem setup by double-clicking
Basic parameters in the Model manager window. Figure 2.13: Basic parameters
panel (p. 33) shows the Basic parameters panel.
Step 6: Calculate a Solution
Figure 2.13: Basic parameters panel
2.8. Step 5: Save the Model

Ansys Icepak automatically saves the model for you before it starts the calculation, but it is a good idea
to save the model (including the mesh) yourself as well. If you exit Ansys Icepak before you start the
calculation, you will be able to open the job you saved and continue your analysis in a future Ansys
Icepak session. (If you start the calculation in the current Ansys Icepak session, Ansys Icepak will simply
overwrite your job file when it saves the model.)
File Save project
Note:
Alternatively, you can click the button in the File commands toolbar.
2.9. Step 6: Calculate a Solution

1. Start the calculation.
Finned Heat Sink
Solve Run solution
Note:
You can click the Run solution button ( ) in the Model and solve toolbar.
Figure 2.14: Solve Panel
2. Match your settings to those of Figure 2.14: Solve Panel (p. 34).
3. Click Start solution to start the solver.
Note:
No universal metric exists for judging convergence; a good indicator is when the solution
no longer changes with more iterations and when the residuals have decreased to a
certain degree. The default criterion is that each residual reduces to a value of less than
except the energy residual, for which the default criterion is . It is a good idea
to judge convergence not only by examining residual levels, but also by monitoring rel-
evant integrated quantities.
Ansys Icepak begins to calculate a solution for the model, and a separate window opens where the
solver prints the numerical values of the residuals. Ansys Icepak also opens the Solution residuals
graphics display and control window, where it displays the convergence history for the calculation.
Upon completion of the calculation, your residual plot will look something like Figure 2.15: Plot of
Solution Residuals (p. 35). You can zoom in the residual plot by using the left mouse.
Note:
The actual values of the residuals may differ slightly on different machines, so your plot
may not look exactly the same as Figure 2.15: Plot of Solution Residuals (p. 35).
Figure 2.15: Plot of Solution Residuals
Finned Heat Sink
4. Click Done in the Solution residuals window to close it.
2.10. Step 7: Examine the Results

Ansys Icepak provides a number of ways to view and examine the solution results, including:
• plane cut views
• object face views
• summary report
The following steps illustrate how to generate and display each view.
Note:
The objective of this exercise is to determine whether the air flow and heat transfer associated
with the heat sink (fans and fins) are sufficient to maintain device temperatures below 65°C.
You can accomplish this by creating different plane cuts and monitoring the velocity vector
and temperature on it. Plane-cut views allow you to observe the variation in a solution variable
across the surface of a plane.
You will use the Plane cut panel to view the direction and magnitude of velocity across a
horizontal plane.
1. To open the Plane cut panel, select Plane cut in the Post menu.
Extra:
You can also open the Plane cut panel by clicking the Plane cut button ( ).
2. Display velocity vectors on a plane cut on the fin side of the enclosure.
Post Plane cut
a. In the Name field, enter the name cut-velocity as shown in Figure 2.16: Plane cut Panel for
cut-velocity (p. 37).
b. In the Set position drop-down list, select X plane through center.
Tip:
Click the drop-down arrow button located next to the Set position text field to open
the drop-down list.
c. Select the Show vectors option.
Step 7: Examine the Results
Figure 2.16: Plane cut Panel for cut-velocity
d. Click Parameters next to the Show vectors option.
e. In the Display options box, select Dart in the Arrow style drop-down menu (Figure 2.17: Plane
cut vectors Panel for cut-velocity (p. 37)). This will display the vectors as dart-like objects.
Figure 2.17: Plane cut vectors Panel for cut-velocity
f. Click Done to exit out of the panel.
Finned Heat Sink
g. Click Create.
h. In the Orient menu, select Orient positive X.
This orients the model as shown in Figure 2.18: Velocity Vectors on the Fin Side of the Enclos-
ure (p. 38). You can see that the maximum velocity occurs at the fan blades. The lowest velocity
occurs between the top fin and the adjacent cabinet wall, and between the bottom fin and the
adjacent cabinet wall.
Extra:
You can also select the positive X orientation by clicking the Orient positive X button
( ).
Figure 2.18: Velocity Vectors on the Fin Side of the Enclosure
i. In the Plane cut panel, turn off the Active option.
This temporarily removes the velocity vector display from the graphics window, so that you can
more easily view the next post-processing object.
Note:
You can later open the Inactive folder in the Model manager window and locate
cut_velocity. The object cut_velocity can be either deleted or reactivated
by dragging it to Trash or to the Post-processing folder, as well as within the right-
click context menu.
3. Display contours of temperature on the fin side of the enclosure.
a. Click New in the Plane cut panel.
b. In the Name field, enter the name cut-temperature.
d. Select the Show contours option and click Parameters.
The Plane cut contours panel opens.
e. Keep the default selection of Temperature.
f. For Shading options, keep the default selection of Banded.
g. For Color levels, select Calculated and then select This object from the drop-down list.
h. Click Apply.
Ansys Icepak computes the color range for the display based on the range of temperatures on
this plane cut.
i. Click Done to save the new settings, close the panel, and update the graphics display.
The graphics display updates to show the temperature contour plot. The actual values of tem-
perature may slightly differ on different systems. You can use the scroll bar to change the x-
location of the plane cut. In addition, the plane cut can be dragged through the model when
you hold down the Shift key and the middle mouse button on the plane. Ensure you click the
edge of the plane cut so as to not move any objects.
Finned Heat Sink
Figure 2.19: Temperature Contours on the Fin Side of the Enclosure (p. 40) shows that heat is
conducted through the fins in both directions away from the sources as well as the thermal
boundary layers resulting from the forced convection.
Figure 2.19: Temperature Contours on the Fin Side of the Enclosure
j. In the Plane cut panel, deselect the Active option.
4. Display velocity vectors superimposed with pressure contours.
a. Click New in the Plane cut panel.
b. In the Name field, enter the name cut-prvelocity.
d. Specify the display of velocity vectors.
i. Select the Show vectors option and click Parameters.
The Plane cut vectors panel opens.
ii. Select Fixed from the Color by drop-down list.
iii. Click the square next to Fixed color and select black from the color palette.
iv. Click Done to close the panel.
e. Specify the display of contours of pressure.
i. Select the Show contours option and click Parameters.
The Plane cut contours panel opens.
ii. In the Plane cut contours panel, select Pressure in the Contours of drop-down list.
iii. For Shading options, keep the default selection of Banded.
iv. For Color levels, select Calculated and then select This object from the drop-down list.
v. Click Done to save the new settings, close the panel, and update the graphics display.
The graphics display updates to show the pressure contour plot superimposed onto the ve-
locity vector plot.
Figure 2.20: Pressure Contours and Velocity Vectors on the Fin Side of the Enclosure (p. 41) shows
isolated regions of high pressure immediately downstream of the fans, including local maxima
at the upstream tips of the fins.
Figure 2.20: Pressure Contours and Velocity Vectors on the Fin Side of the Enclosure
f. In the Plane cut panel, turn off the Active option.
5. Display contours of temperature on all five high-power devices.
An object-face view allows you to examine the distribution of a solution variable on one or more
faces of an object in the model. To generate an object-face view, you must select the object and
specify both the variable to be displayed (for example, temperature) and the attributes of the view
(for example, shading type).
You will use the Object face panel to create a solid-band object-face view of temperature on all
five high-power devices and on the backing plate.
a. To open the Object face panel, select Object face in the Post menu.
Finned Heat Sink
Post Object face
Extra:
You can also open the Object face panel by clicking the Object face button ( ).
b. In the Name field, enter the name face-tempsource.
c. In the Object drop-down list, click source.1, hold down the Shift key, and click source.1.4 to
select all the sources, and click the Accept button.
d. Select the Show contours option.
e. Click Parameters next to the Show contours option.
The Object face contours panel opens.
f. In the Object face contours panel, keep the default selection of Temperature in the Contours
of drop-down list.
g. For Shading options, keep the default selection of Banded.
h. For Color levels, select Calculated and then select This object from the drop-down list.
The graphics display updates to show the temperature contours on the sources.
j. Use your right mouse button to zoom in and look more closely at each source.
Figure 2.21: Temperature Contours on the Five Devices (p. 44) shows a view with the temperature
contours on all five sources. The temperature distributions are similar for all sources: warm in
the center and decreasing in temperature toward the edges of the source. Temperature distribu-
tions on the top and bottom sources are similar to each other, as are distributions on the two
remaining sources.
Note:
To view the temperature contours on an individual source, hold down the Shift key
and drag a box around a source object using the left mouse button. The source object
will show as highlighted in the Model manager window. Right-click the source object
to display the context menu and select Create Object face(s) Separate. Ansys
Icepak displays the Object face panel for that particular object. Change the settings
to match the ones used above for all source objects and click Create.
Finned Heat Sink
Figure 2.21: Temperature Contours on the Five Devices
k. In the Object face panel, deselect the Active option.
6. Display line contours of temperature on the backing plate.
a. Click New in the Object face panel.
b. In the Name field, enter the name face-tempblock.
c. In the Object drop-down list, select block.1 and click Accept.
d. Select the Show contours option and click Parameters.
The Object face contours panel opens.
e. In the Object face contours panel, keep the default selection of Temperature in the Contours
of drop-down list.
f. For Contour options, deselect Solid fill and select Line.
g. For Level spacing, select Fixed and set the Number of contour lines to 200.
h. For Color levels, select Calculated and then select This object from the drop down list.
The graphics display updates to show the temperature contours on the block. Figure 2.22: Tem-
perature Contours on the Backing Plate (p. 45) shows that most of the heat is confined to the
region near the sources. The maximum temperature occurs near the middle three sources.
Figure 2.22: Temperature Contours on the Backing Plate
j. Click Done in the Object face panel to close the panel. Deselect the Active option for the object
face in the Model manager window.
7. Utilize the Transparency slider in the Plane cut panel to help visualize multiple plane cuts simul-
taneously.
a. Refer to Figure 2.16: Plane cut Panel for cut-velocity (p. 37). Select Active in the Plane cut panel
to display in the graphics display window. Select the check box for the Transparency slider in
order to enable transparency. Click and drag the slider between the allowable values 0.00–0.99
to control the degree of transparency. In the Plane cut panel, deselect the Active option.
b. Click Done in the Plane cut panel to close the panel.
c. Figure 2.23: Example of Transparency Feature with Multiple Plane cut Contours (p. 46) is a com-
bination of two plane cut temperature contours and a partially transparent pressure contour as
an example of the Transparency feature. Notice that the single, semi-transparent pressure
contour allows concurrent visualization of the temperature profiles immediately next to the
block.
Finned Heat Sink
Figure 2.23: Example of Transparency Feature with Multiple Plane cut Contours
8. Create a summary report of object-specific solution data. Summary reports can provide physical
information from the solution about specific Model objects, Groups objects, Post-processing objects
and Points objects. Follow the steps below to create a summary report:
a. First, make the post-processing object cut-temperature active again by accessing the context
menu under the Inactive node in the Model manager window.
b. Report Summary report
c. Click New in the Define summary report panel five times to create 5 rows of Objects.
d. In the first row, select object block.1, then click Accept. In the Value drop-down menu,
select Heat flow.
Note:
Although you did not change the default settings of the check boxes Comb and
Mesh, you may encounter projects in which you need to change these. Comb
refers to “combined”: The report generates a single, combined value for all the
sides selected; deselecting the option would report the side values separately.
Mesh allows you to report on the reduced mesh of the selected object in the
case that an object intersects with other objects and the mesh in the intersecting
region might not necessarily belong to the object of interest.
e. In the second row, use the Shift key to select all 3 fans, then click Accept. In the Value
drop-down menu, select Volume flow.
f. In the third row, use the Shift key to select all 5 sources, then click Accept. In the Value
drop-down menu, select Heat flow.
g. In the fourth row, use the Shift key to select all 10 plates, then click Accept. In the Value
drop-down menu, select Heat flow.
Finned Heat Sink
h. In the fifth row, select post cut-temperature, then click Accept. Keep the default settings
in the other fields.
i. Click Write to generate a panel for the object summary report (Figure 2.24: Report summary
data Panel (p. 48)). Examine the values reported and confirm they are consistent with the
physics of the model. Click Done to exit out of this panel, then Close to exit the Define
summary report panel.
Figure 2.24: Report summary data Panel
9. Save the post-processing objects created.
a. Select Save post objects to file in the Post menu.
b. Click Save in the File selection window that opens.
Upon saving the project, all objects created during post-processing are saved within a
post_objects file for future retrieval.
2.11. Step 8: Summary

In this tutorial, you have determined the ability of the specified heat sink to maintain source temperatures
below 65°C. Post-processing results show that the maximum source temperature is about 60°C, indicating
that the heat sink provides adequate cooling for the sources.
In addition, you have learned the basic workflow of an Ansys Icepak project, including model building,
mesh generation, problem setup, solution calculation, and post-processing as well essential features
and functions that you will likely use in later tutorials or your own projects.
We repeat some of the tips and best practices found in this tutorial for your convenience:
Step 8: Summary
1. Best Practices
a. Check the default materials, properties, and operating conditions under the Defaults tab in the
Basic parameters panel. These defaults often render some specifications unnecessary.
b. Use the Show objects by type feature to verify your model objects by type.
c. Use the Check model feature to ensure there are no problems with the model.
d. View the HTML summary report (View Summary (HTML)) to ensure proper specification of
geometries, properties, and materials for each object.
e. Select the Allow minimum gap changes option in the Misc tab of the Mesh control panel to
allow Ansys Icepak to avoid unnecessary meshing due to inadvertent misalignments in the
model. This is suitable for this tutorial but may not be in other projects.
f. Select Normal in the Mesh parameters field when flow structures require finer grids than possible
with Coarse meshing.
g. Use the Problem setup wizard for guided problem setup. Edit the problem setup if needed
using the Basic parameters panel.
h. Save the model and mesh before starting the solution so that you can open the saved job and
continue analysis in a future session.
i. Judge convergence by monitoring residual levels as well as relevant integrated quantities, which
should eventually stop changing significantly with more iterations.
2. Tips and Tricks
a. Explore the several methods to complete a task as you work through a problem in Ansys Icepak.
For example, you can edit model object geometries by using their object edit panel, or you can
use the Edit window in the bottom right-hand corner while having the object node selected in
the Model manager window. Use the options best suited for you to help streamline your
workflow.
b. Choose blocks and plates according to your needs. Blocks and conducting thick plates allow six-
sided control for meshing and thermal specifications. Conducting thin plates, however, have no
physical thickness and therefore allow for only two-sided control.
c. Remove object names by clicking the Display object names button ( ) to reduce visual clutter
in the graphics window.
d. Use the Reset button in the Basic settings panel to have Ansys Icepak estimate dimensionless
numbers (for example, the Reynolds and Peclet numbers for forced convection) and determine
the appropriate flow regime.
e. Hold your mouse pointer over any selection in the Problem setup wizard to have a text bubble
appear for additional information on the selection.
f. Use the Transparency slider in the post-processing object edit panels to improve visualization
of post-processing objects.
Finned Heat Sink
g. Use the post summary report to view an object-specific summary of the solution results.
2.12. Step 9: Additional Exercise

To determine the effectiveness of the heat sink under conditions involving the failure of the middle
fan, you can either deactivate fan.1.1 or edit it fan.1.1 to fail. To make it fail, edit it by double-clicking
on fan.1.1 in the model manager window, go to the Properties tab and select Failed under the Options
tab, assign a free area ratio of 0.3, and click Done. Mesh the model and solve it again using a different
solution ID. Compare the new results with the previous setup.
Note:
When you are finished examining the results, you can end the Ansys Icepak session by
clicking Quit in the File menu.
File Quit
Chapter 3: RF Amplifier
3.1. Introduction
This tutorial demonstrates how to model an RF amplifier using Ansys Icepak as well as many features
and functions essential to any Ansys Icepak project. For the sake of brevity, many of the later tutorials
do not cover basic steps or explain the steps in detail as those tutorials assume you have completed
this and/or the last tutorial (Finned Heat Sink (p. 5)) beforehand.
• Create a new project.
• Create a model using openings, fans, sources, enclosures, PCBs, heat sinks, and walls.
• Use non-conformal meshing.
• Set up a simulation with various physical conditions and parameters, including turbulence and natural
convection.
• Calculate a solution.
• Post-process your results by using power and temperature limits, object faces, plane cuts, isosurfaces
and variation plots.
Note:
3.2. Prerequisites
This tutorial assumes that you have little experience with Ansys Icepak but that you are generally famil-
iar with the interface. If you are not, review the Sample Session in the Icepak User’s Guide.

RF amplifiers are typically sealed enclosures that are placed within larger systems. They present a chal-
lenge from the thermal management perspective because no direct exchange of air exists between the
interior of the amplifier and the ambient. The common method of cooling such subsystems is to mount
a large heat sink on the amplifier housing that cools all the devices within the enclosure. A simplified
version of an RF amplifier (Figure 3.1: Schematic of the RF Amplifier (p. 52)) will serve as the model for
RF Amplifier
this tutorial. There will be free convection inside the amplifier and forced convection in the external
domain.
Figure 3.1: Schematic of the RF Amplifier

1. Start Ansys Icepak, as described in Starting Ansys Icepak from the User’s Guide.
3. Specify the name rf_amp for your project and click Create.
Note:
its default orientation, select the Home position in the Orient menu. Alternatively, you
can click the Home position icon ( ) above the graphics window or press the H key.

To build the model, you will first resize the cabinet to its proper size. Then you will create the amplifier
housing, devices (heat sources), PCB, heatsink, fan and other geometrical objects.
1. Resize the default cabinet and create an opening on one side of the cabinet.
Model Cabinet
RF Amplifier
Select the cabinet in the Model manager window and specify the following in the object geometry
window:
Note:
After selecting the object to be edited in the Model manager window, there are several
ways you can open the Edit panel:
• Double-click the object in the Model manager window, or
– Type Ctrl+e, or
– Right-click the object in the Model manager window and scroll to Edit object, or
– Click the Edit button in the object geometry window, or
– Click the Edit object icon ( ) in the model toolbar
Figure 3.2: The Cabinet Geometry Tab Panel
One side of this cabinet has an opening. To assign Properties on this boundary, in the Properties
tab of the Cabinet object panel (Figure 3.3: The Cabinet Boundary Panel (p. 55)):
a. Change the Max y Wall type to be an Opening.
b. Click Done to accept the inputs and close the panel.
Figure 3.3: The Cabinet Boundary Panel
2. Create the Y and Z faces of the amplifier housing as an enclosure using the enclosure object.
Click the Create enclosures icon ( ) in the model toolbar, then specify the following Name and
dimensions:
In the Properties tab specify the followings:
a. Change the Boundary type to Open for Min X and Max X. For others, retain the boundary type
as Thin.
b. Specify the Solid material as Polystyrene-rigid-R12.
Tip:
You have to scroll down the list to find this material.
c. Click Done.
RF Amplifier
Figure 3.4: The Enclosure Panel
3. Create a wall on the Xmin face of the amplifier housing to cover the Xmin side of the enclosure.
Click the Create walls icon ( ) in the model toolbar to create a new wall.
In the object edit window, name the wall Xmin and change the plane to Y-Z.
4. Use Morph Edges to align the wall and then specify the wall properties.
Note:
Although you are using the align tools to place the wall at the desired locations, you
could also specify the dimensions/locations of the wall in the Geometry tab and achieve
the same result. However, the align tools are faster and thus the recommended method.
To start the process, click the Morph edges icon ( ) in the model toolbar. Now, follow the step-
by-step procedure described below:
a. Select the Zmax edge of the wall, indicated by the red edge in the figure (Figure 3.5: Schematic
Showing Edge Identities for Alignment (p. 57)) by left mouse clicking it in the graphical window.
Notice that it turns red to indicate that it has been selected.
b. Click the middle mouse button to accept this edge.
c. Select the lower Zmax edge of the enclosure, indicated by the yellow edge in the figure (Fig-
ure 3.5: Schematic Showing Edge Identities for Alignment (p. 57)) with the left mouse button.
Notice that it turns yellow to indicate its selection.
Figure 3.5: Schematic Showing Edge Identities for Alignment
d. Click the middle mouse button to accept the transformation. The wall Xmin should have now
been moved and resized. Now the wall should extend to the entire Xmin side of the enclosure.
To specify the remaining wall dimension, stay in the Morph edges mode and complete the following
steps:
a. Click the Zmin edge of the wall with the left mouse button. Be sure that the Zmin edge of the
wall (and not the enclosure edge) is highlighted in red. By repeatedly clicking the left mouse
button, Ansys Icepak cycles through all possible edges.
b. Click the middle mouse button to accept.
c. Using the left mouse button, click the lower Zmin edge of the enclosure.
d. Click the middle mouse button to accept. The wall now forms the Xmin face of the enclosure.
RF Amplifier
e. Click the right mouse button to exit the Morph edges mode.
The resulting model is shown in Figure 3.6: Geometry with Wall (p. 58) with shading to highlight
new definitions. Shading is available under the Info tab in most panels.
Figure 3.6: Geometry with Wall
Double-click the newly created wall object (Xmin) in the Model manager window to open the Walls
panel. Specify the following properties to the wall in the Properties tab.
a. Specify a Wall thickness of 1 mm (0.001 m).
b. Specify the Solid material as Polystyrene-rigid-R12 under Plastics.
c. Specify the External conditions as Heat transfer coefficient and click the Edit button.
The Wall external thermal conditions panel opens.
i. Select Heat transfer coeff in the Thermal conditions group box.
ii. Set the Heat transfer coeff to 5 W/K-m2.
iii. Click Done to close the Wall external thermal conditions panel.
iv. Click Done to close Walls panel (Figure 3.7: The Walls Panel (p. 59)).
Figure 3.7: The Walls Panel
5. Create the PCB.
The PCB will cover the Xmax side of the enclosure.
a. Click the Create printed circuit boards icon ( ) in the Model toolbar to create a PCB and
double-click the PCB object in the Model manager window.
b. Specify the following in the geometry window:
RF Amplifier
c. Specify the Trace layer type as Detailed and specify the parameters under Trace layer para-
meters (make sure that you enter both columns) in the Properties tab as shown in Figure 3.8: The
Printed circuit boards Panel (p. 60). Click the Add layer button 3 more times. There is a total of
four internal layers.
Note:
Specify the layer thicknesses in microns.
Notice that the Effective conductivity in plane and normal directions are updated when you
click the Update button (Figure 3.8: The Printed circuit boards Panel (p. 60)).
Figure 3.8: The Printed circuit boards Panel
d. Click Done to close the Printed circuit boards panel.
6. Create the devices as 2D sources.
There are 12 devices on the bottom side of the PCB. Create these devices as 2D sources. The following
steps show you how to create one and then use the copy utility to create the remaining 11 sources.
a. Click the Create sources icon ( ) in the model toolbar to create a source and double-click the
source object in the Model manager window.
b. Specify the following source name, dimensions, and properties.
c. In the Properties tab, specify the Total power as 7 W (Figure 3.9: The Sources Panel (p. 62))
and click Done.
RF Amplifier
Figure 3.9: The Sources Panel
d. Create two copies of the source and separate them by 0.055 m in the Z direction. Follow the
steps below for copying the source object.
i. Right-click the source object and choose the Copy option. Alternatively, click the source object
in the Model manager window and press Ctrl+C to bring up the Copy panel.
ii. Specify the Number of copies as 2.
iii. Select the Translate option.
iv. Specify a Z offset of 0.055 m.
v. Click Apply to copy the object.
Figure 3.10: The Copy source device Panel
e. Similarly, create the other source objects (devices) by copying the sources created in the previous
steps.
i. Click and select device, then while holding down the Ctrl key, select device.1, and
device.2. Right-click and choose the Copy option, or press Ctrl+c.
ii. Specify the Number of copies as 3.
iii. Turn on the Translate option.
iv. Specify a Y offset of 0.064 m.
RF Amplifier
v. Click Apply to copy the object.
Note:
Following these two copy actions, you should now have 12 sources (Figure 3.11: Geo-
metry with Devices (p. 64)) in a four rows by three columns pattern.
Figure 3.11: Geometry with Devices
7. Create the heat sink.
You will create an extruded fin heat sink with the flow in the Y direction to remove heat from the
PCB.
a. Click the Create heat sinks icon ( ) in the Model toolbar to create a heat sink and double-
click the heat sink object in the Model manager window. Specify the following dimensions in
the geometry window.
b. In the Heat sinks object panel, select the Geometry tab, and specify a Base height of 0.004
m and an Overall height of 0.04 m.
c. Specify the properties of the heat sink as shown in Figure 3.12: The Heat sinks Panel (p. 65) below.
Note that you are not changing parameters in the Flow/thermal data, Pressure loss, or Interface
tabs.
Figure 3.12: The Heat sinks Panel
d. Click Done to close the Heat sinks panel.
RF Amplifier
8. Create the fan.
For this model, we will make use of Ansys Icepak’s fan library and search tool.
a. Select the Library tab in the model manager window (Figure 3.13: Search Fan library Panel (p. 67)).
b. Right-click Libraries in the Model manager window and choose Search fans.
The Search fan library dialog appears.
i. In the Physical tab, deactivate the Min fan size and enter 80 mm for the Max fan size.
ii. Select the Thermal/flow tab, enable the Min flow rate option and specify a Min flow rate
of 80 cfm.
Note:
The minimum flow rate used in the search criteria implies the minimum free flow
of the fans.
iii. Click the Search button.
Note:
Ansys Icepak lists all the fans in its libraries that satisfy these conditions.
c. Select the fan called delta.FFB0812_24EHE in the Name column by clicking it.
d. Click Create to load the fan into the model.
Figure 3.13: Search Fan library Panel
e. Now, specify the location of the fan. Resize the fan geometry as shown in Figure 3.14: The Fans
Panel (p. 68). Note the plane orientation is X-Z.
RF Amplifier
Figure 3.14: The Fans Panel
The final geometry should look like Figure 3.15: The Final Geometry (p. 69).
Figure 3.15: The Final Geometry
f. Display objects by type.
You can enable the display of all object types, the filtering of blocks by type (fluid, solid, network,
hollow), and the display of blocks with traces and/or CAD block. This feature is useful here to
view the otherwise unseen devices behind the heat sink. Generally, this also aids in model veri-
fication.
i. Model Show objects by type
ii. The Show objects by type panel appears as shown in Figure 3.16: Show objects by type
Panel (p. 70).
RF Amplifier
Figure 3.16: Show objects by type Panel
iii. Click Display to show the devices. The model then appears as in Figure 3.17: Displaying Objects
of Type Source (p. 70).
Figure 3.17: Displaying Objects of Type Source
Step 3: Create Assemblies
iv. Click Close to exit the Show objects by type panel.
g. Check the definition of the modeling objects to ensure that you specified them properly.
View Summary (HTML)
Note:
The HTML version of the summary displays in your web browser. The summary displays
a list of all the objects in the model and all the parameters that have been set for
each object. You can view the detailed version of the summary by clicking the appro-
priate object names or property specifications. If you notice any incorrect specifications,
you can return to the appropriate modeling object panel and change the settings in
the same way that you originally entered them.
3.6. Step 3: Create Assemblies

For both organizational purposes and to have a finer mesh in the fan and enclosure, you will create
two assemblies. The first assembly consists of the RF amplifier and heat sink; the second assembly
consists only of the fan.
1. To create the amplifier assembly:
a. Select the positive X view by either using the icon in the shortcut menu or simply press Shift+X
and then S to scale to fit the view in the graphics window.
b. While pressing Shift, drag a bounding box around the amplifier using the left mouse button.
Do not drag the bounding box around the fan. Release the mouse button and notice that all of
the objects forming the amplifier and heat sink have been selected in the Model manager
window.
c. Right-click the highlighted enclosure ("Housing") in the Model manager window and select
Create and then Assembly from the list. You have now added all of the selected objects to the
assembly.
d. In the Object geometry window, rename assembly.1 to amplifier and click Apply.
2. Create a new assembly for the fan object:
a. Click the Create assemblies icon ( ) in the model toolbar to create a new assembly.
b. In the Model manager window, use the left mouse button to drag the fan,
delta.FFB0812_24EHE, into the new assembly to add the fan to this assembly.
c. In the Object geometry window, rename this assembly as fan and click Apply.
RF Amplifier
Figure 3.18: Two Assemblies

Before generating a mesh, specify the slack values for the assemblies.
Note:
Slack values represent a finite offset from an object to a non-conformal mesh boundary
and are required when meshing assemblies separately. Selecting small slack values can
decrease the total number of cells in the mesh with a negligible change in accuracy.
On the other hand slack values that are too large may cause excessive mesh bleeding.
It is good practice to set slack values such that two or three cells fit in the slack region.
Note that in this particular model the gap between the two assemblies is large enough
to accommodate nonzero slack values. Refer to Zero Slack with Non-Conformal Mesh-
ing (p. 435) for more discussion on slack values.
1. Edit both assemblies (right-click the assembly name in the model toolbar and select Edit), then select
the Meshing tab.
2. Toggle Mesh separately and then specify the slack values indicated in the following table. Make
sure you remember to add slack values to both assemblies.
Table 3.1: Slack Values for the Amplifier and Fan
Name Min X Min Y Min Z Max X Max Y Max Z

Amplifier 0 0.02 0.01 0 0.05 0.01
Fan 0.01 0 0.01 0.01 0.05 0.01
RF Amplifier
Figure 3.19: Fan Assemblies Panel
3. To create the mesh, go to Model Generate Mesh. The Mesh control panel (Figure 3.20: The
Mesh control Panel (p. 75)) appears. You can also open the Mesh control panel by clicking the
Generate mesh icon ( ) in the shortcut menu.
Figure 3.20: The Mesh control Panel
RF Amplifier
4. First, generate a coarse mesh by choosing Coarse in the Mesh parameters drop-down list in the
Global tab, as shown in Figure 3.20: The Mesh control Panel (p. 75). Click Generate to create a
mesh.
Note:
If you have unchecked Allow minimum gap changes in the Misc tab, the Minimum
separation warning will appear. This warning message appears when the minimum gap
specified is more than 10% of the smallest sized object in the model. Select Change
value and mesh if the warning message pops up.
5. To view the mesh, display a plane cut view through the center of the cabinet, perpendicular to the
fins (y-z plane).
6. To create a plane cut, follow these steps:
a. Click the Display tab at the top of the Mesh control panel.
b. Toggle Display mesh and Cut plane.
c. Under Plane location, set position to X plane through center in the drop-down list.
d. Press Shift+X to orient to the positive X direction and view the newly created cut plane.
e. Move the plane using the slider bar to see different views.
Make sure that the amplifier assembly is expanded and inspect the cells adjacent to the heat sink
fins. Notice that the resolution is coarse (Figure 3.21: Coarse and Fine Mesh (p. 77)), with only a
couple of cells between the fins. As the flow passes between the fins, the boundary layers will grow
and their degree of resolution will dictate the accuracy of the simulation. You want to have at least
three to four cells between the fins to adequately resolve the growth of the boundary layers. Refining
the mesh results in better resolution.
7. Select Normal in the Mesh parameters drop-down list in the Settings tab. Click Generate and in-
spect the resulting mesh. Note that this has increased the number of cells between adjacent fins
(Figure 3.21: Coarse and Fine Mesh (p. 77)), providing better resolution of the boundary layers.
You can display the mesh on selected objects or the cut plane by using the context menu in the
graphics window. To display the context menu, hold down the Shift key and press the right mouse
button anywhere in the graphics window. Select Display mesh or Display cut plane mesh in the
context menu and the mesh will be displayed on selected objects or the cut plane will be displayed.
It is also a good practice to select the Quality tab and review the Face Alignment, Volume, and
Skewness. The histograms show the quality metric (Face Alignment, Volume or Skewness) versus
the number of cells. Clicking the bars that form the histogram displays the cells with that value in
the graphics window.
Figure 3.21: Coarse and Fine Mesh
8. Once you have explored the mesh quality, click Close to dismiss the Mesh control dialog box.

Before starting the solver, you will first review estimates of the Reynolds and Peclet numbers to check
that the proper flow regime is being modeled.
1. Check the values of the Reynolds and Peclet numbers.
a. Click the Reset button (Figure 3.22: The Basic settings Panel (p. 78)).
RF Amplifier
Figure 3.22: The Basic settings Panel
b. Check the values printed to the Message window.
The Reynolds and Peclet numbers are approximately 55000.0 and 40000.0 respectively, so the
flow is turbulent. Ansys Icepak recommends setting the flow regime to turbulent.
Note:
These values are only estimates, based on the current model setup. Actual values may
vary, and may need to be verified, depending on your design.
c. Click Accept to save the solver settings.
2. Using the Problem setup wizard, enable turbulence modeling using the zero equation turbulence
model and neglecting radiation heat transfer.
a. In the Model manager window, right-click Problem setup ( ) and then select Problem setup
wizard. Figure 3.23: Problem setup wizard panel at step 1 of 14 (p. 79) shows what appears. The
Problem setup wizard provides a simple interface with user guidance for defining the physics
of the model.
b. For step 1 of 14, indicated in the bottom-left corner of the Problem setup wizard panel, keep
the default settings for the check boxes. Click Next.
c. For step 2 of 14, select Flow is buoyancy driven (natural convection) as in Figure 3.24: Problem
setup wizard panel at step 2 of 14 (p. 80), since natural convection is not negligible inside the
RF amplifier. Click Next.
RF Amplifier
Note:
Hold your mouse pointer over any selection in the Problem setup wizard to have a
text bubble appear for additional information on the selection, as shown in Fig-
ure 3.24: Problem setup wizard panel at step 2 of 14 (p. 80).
d. For step 3 of 14, keep the default setting of Use Boussinesq approximation for the natural
convection model.
e. For step 4 of 14, keep the Operating pressure at the default value of 101325.0 N/m2. Select
Set gravitational acceleration and leave the default values for all directions, as shown in Fig-
ure 3.25: Problem setup wizard at step 4 of 14 (p. 81). Click Next.
f. For step 5 of 14, select Set flow regime to turbulent to enable turbulence modeling, shown in
Figure 3.26: Problem setup wizard at step 5 of 14 (p. 81). Click Next.
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g. For step 6 of 14, select Zero equation (mixing length) to choose the zero equation turbulent
model, shown in Figure 3.27: Problem setup wizard at step 6 of 14 (p. 82). Click Next.
h. For step 7 of 14, turn off radiation by selecting Ignore heat transfer due to radiation. Click
Next.
i. For step 9 of 14, keep the check box clear to ignore solar radiation. Click Next.
j. For step 10 of 14, keep the default setting of Variables do not vary with time (steady-state)
for steady-state simulation. Click Next.
k. For step 14 of 14, keep the check boxes clear to ignore altitude effects. Finally, click Done to
finish the Problem setup wizard. These settings now fully define the problem setup.
Note:
You can edit these settings and other aspects of the problem setup by double-clicking
( ) Basic parameters in the Model manager window. Figure 3.28: Basic parameters
panel (p. 83) shows the Basic parameters panel that appears.
Figure 3.28: Basic parameters panel
3. Return to the Basic settings panel, specify the number of iterations as 300, click Reset and then
Accept again.
4. Set up the temperature limits for all the sources.
Model Power and temperature limits
a. Figure 3.29: Panel of Power and temperature limit setup (p. 84) shows the required settings for
the next few steps.
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Figure 3.29: Panel of Power and temperature limit setup
b. Enter a new value of 60 C for Default temperature limit.
c. Click All to default.
d. Click Apply and then click Accept to close the panel.
Note:
Ansys Icepak uses the default temperature limit during post-processing to identify
components that exceed their limits or components that are close to this limit. Ansys
Icepak does not use this value to solve the problem.

Ansys Icepak will save the model for you automatically before it starts the calculation, but it is a good
idea to save the model yourself as well. If you exit Ansys Icepak before you start the calculation, you
will be able to open the job you saved and continue your analysis in a future Ansys Icepak session. (If
you start the calculation in the current Ansys Icepak session, Ansys Icepak will simply overwrite your
job file when it saves the model.)
File Save project
Note:
You can click the save button ( ) in the File commands toolbar.

1. Create monitors.
Note:
It is good practice to monitor the solution progress for certain objects. Dragging the
object in the Model manager window and placing it in the Points folder can accomplish
this.
a. Drag device.2 and cabinet_default_side_maxY into the Points folder.
b. Right-click the cabinet_default_side_maxY in the Points folder.
c. Select Edit and deselect Temperature and select Velocity (Figure 3.30: The Modify point
Panel (p. 85)).
d. Click Done to accept the modifications and to dismiss the per-object’s Modify point panel.
Figure 3.30: The Modify point Panel
2. Start the calculation.
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Solve Run solution
a. Since this particular example has neither radiation nor blocks with joule heating, ensure that
you select Disable radiation and deselect Disable varying joule heating.
Note:
Disable radiation instructs Ansys Icepak not to calculate radiation parameters

for the model. For cases in which your model has blocks with joule heating, only
then should you select Disable varying joule heating. Otherwise, leave the option
deselected. Refer to Using the Solve Panel to Set the Solver Controls in the Ansys
Icepak User’s Guide for more information on the settings in the Solve panel.
b. Select Write overview of results when finished in the Results tab.
c. Click the Start solution button to start the solver. While iterating the solution, windows will
appear showing convergence history, Figure 3.31: Convergence Plot (p. 87) and Figure 3.32: Mon-
itor Plot - Temperature (p. 88).
Note:
Alternatively, you can click the Run solution icon ( ) in the model and solve toolbar
to display the Run solution panel.
Figure 3.31: Convergence Plot
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Figure 3.32: Monitor Plot - Temperature
Figure 3.33: Monitor Plot - Velocity

Once the model has converged (Figure 3.31: Convergence Plot (p. 87) and Figure 3.32: Monitor Plot -
Temperature (p. 88)), Ansys Icepak automatically generates a solution overview report. This report
contains detailed information, such as object-based mass and volumetric flow rates, fan operating
points, heat flows for objects with specified power, heat flows for objects that communicate with the
ambient, maximum temperatures, and overall balances.
Carefully review the solution overview and note that the solution satisfies conservation of mass and
energy (scroll to the bottom of the report). Also note the fan operating point. The solution overview is
automatically saved and can be reopened from Report Solution overview Create.
1. Compare the object temperature values for all sources with the temperature limits assigned.
Post Power and temperature values
The Power and temperature limit setup panel appears.
a. Click Show too hot.
The Power and Temperature limit setup show the default temperature limit and the resulting
maximum temperature value for each source next to them.
If an assembly is expanded in the Model manager window and if the resulting temperature of
any object exceeds the temperature limit specified, Ansys Icepak shows all the critical objects in
red color.
b. Click Accept to close the dialog box.
2. Create object faces.
Note:
Ensure that the amplifier and fan assemblies are expanded, so that the fins are visible.
a. Press Shift+Z to orient the view in the positive Z direction.
b. To create an object face, click the Object face icon ( ) in the shortcut toolbar.
c. In the Object drop down list, specify heatsink.1 as the object and click Accept.
d. Select Show contours and click the Parameters button (adjacent to show contours) to access
the Object face contours edit dialog box.
i. Select This object in the drop-box adjacent to Calculated to use the object-based range.
ii. Click Done to close the Object face contours panel.
RF Amplifier
e. Click Done to close the Object face panel.
Note:
You can also create contours on heatsink.1 by selecting this object in the Model
manager window and right-clicking to display the context menu. Select Create>Object
face(s)>Separate and the Object face panel will appear. The Object face panel is
displayed for that particular object.
Figure 3.34: Object face Panel
Note:
Using the mouse, rotate the heat sink to examine the surface temperature distribution.
Notice that the location of the devices is clearly discernible on the bottom of the heat
sink. Also note that the devices get progressively hotter in the flow direction (Fig-
ure 3.35: Temperature Contours on the Heat Sink Object Face (p. 91)).
Figure 3.35: Temperature Contours on the Heat Sink Object Face
Note:
Notice that face.1 has now appeared in the Model manager window in the Post-
processing folder. Right-click face.1 and note that you can make it active, edit it, or
delete it. You can move face.1 into the Inactive folder by dragging and dropping
face.1 within the Model manager window. You can make face.1 active again or
delete it by dragging it to Trash or to the Post-processing folder, as well as with the
right-click dialog.
3. Create plane cuts.
a. To create a plane cut, click the Plane cut icon ( ) in the shortcut toolbar.
b. Select the Set position as Point and normal and select Show vectors, as shown in the panel
below. Enter PX, PY, and PZ, as well as NX, NY, and NZ according to Figure 3.36: Plane cut Pan-
el (p. 92). You may also specify the point’s coordinates as 0.680 by using the slider at the
bottom of the Plane location box in the same panel.
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Figure 3.36: Plane cut Panel
c. Click the Parameters button adjacent to Show vectors.
d. Select Uniform in Display options group box and specify value as 5000. The Uniform option
for the velocity will uniformly place the vectors among the 5000 data points.
e. Select This object in the drop-box adjacent to Calculated and click Done to close the panel.
The vector plots are shown in the graphics window (Figure 3.37: Plane Cut of Velocity Vector
Field (p. 93)).
Figure 3.37: Plane Cut of Velocity Vector Field
Note:
Examining the vector plot, we can see that the flow pattern is symmetric, with two large
recirculating zones adjacent to the fan. Zoom into the region directly in front of the fan
and notice that two smaller recirculating zones exist in front of the hub. These local effects
can be important when objects are close to the hub region.
Note:
You can move a plane cut through a model by pressing the Shift key, holding down the
middle mouse button on an edge of the plane cut and dragging the plane cut through
the model in the graphics window.
4. Create isosurfaces.
a. Click the Isosurface icon ( ) in the shortcut toolbar.
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b. Specify Temperature as the Variable, input a Value of 55°C, and select Show contours and
click Parameters. In the Isosurface contours panel, select Smooth for Shading options and
This object in the drop-box adjacent to Calculated. Click Done.
c. Click Update in the Isosurface panel and notice that an isosurface has been placed around all
of the sources, indicating that they have temperatures equal to 55°C (Figure 3.38: Temperature
Isosurface Contour of 55°C for Sources (p. 94)).
Figure 3.38: Temperature Isosurface Contour of 55°C for Sources
d. Now, change the Variable to Speed and input a Value of 4. Click Update. Notice that the regions
with velocities in excess of 4 m/s are now displayed (Figure 3.39: Temperature Contours on
Isosurface of Speed 4 m/s (p. 95)).
Figure 3.39: Temperature Contours on Isosurface of Speed 4 m/s
5. Utilize the Transparency slider to help visualize multiple post-processing objects simultaneously.
a. With the previously created isosurface still active, select the plane cut (cut.1) in the Model
manager window and select Active to make it visible again.
b. Edit iso.1. Select the Transparency check box, shown in Figure 3.40: Isosurface Panel with
Transparency Enabled (p. 95). Set the value to 0.63.
Figure 3.40: Isosurface Panel with Transparency Enabled
c. Click Done to show the isosurface and plane cut simultaneously (Figure 3.41: Concurrent Visual-
ization of Semi-Transparent Isosurface and Opaque Plane cut (p. 96)). Notice the semi-transparency
of the isosurface allows the concurrent visualization of the opaque velocity flow field near the
fan.
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Figure 3.41: Concurrent Visualization of Semi-Transparent Isosurface and Opaque Plane

cut
Note:
You can access the Transparency slider in the following post-processing objects:
Object face, Plane cut, and Isosurface.
6. Create a summary report of object-specific solution data. Summary reports can provide physical
information from the solution about specific Model objects, Groups objects, Post-processing objects
and Points objects. Follow the steps below to create a summary report:
a. First, make the post-processing object face.1 active again by accessing the context menu under
the Inactive node in the Model manager window.
b. Report Summary report
c. Click New in the Define summary report panel three times to create 3 rows of Objects.
d. In the first row, select object heatsink.1, then click Accept. In the Value drop-down menu, select
Heat flow.
Note:
Although you did not change the default settings of the check boxes Comb and
Mesh, you may encounter projects in which you need to change these. Comb refers
to “combined”: The report generates a single, combined value for all the sides selected;
deselecting the option would report the side values separately. Mesh allows you to
report on the reduced mesh of the selected object in the case that an object intersects
with other objects and the mesh in the intersecting region might not necessarily be-
long to the object of interest.
e. In the second row, select the fan, object delta.FFB0812_24EHE, then click Accept. In the Value
drop-down menu, select Volume flow.
f. In the third row, select post face.1, then click Accept. In the Value drop-down menu, select
Temperature.
g. Click Write to generate a panel for the object summary report (Figure 3.42: Report summary data
Panel (p. 98)). Examine the values reported and confirm they are consistent with the physics of
the model. Click Done to exit out of this panel, then Close to exit the Define summary report
panel.
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7. Create variation plots.
a. Click the Variation plot icon ( ) in the shortcut toolbar.
Note:
Before creating the variation plots, ensure that the amplifier assembly is expanded,
so that the fins are visible. Next, press Shift+Z to orient the view in the positive Z
direction.
b. Within the variation plot dialog box, complete the following:
i. Specify the Variable as UY.
ii. Click the From screen button.
iii. Click the center of the heat sink fins.
iv. Click Create.
c. An X-Y plot of UY velocity versus Z coordinate is now visible (Figure 3.43: Variation Plot of UY
Velocity Versus Z Coordinate (p. 99)). Toggle the Symbols button and notice that the velocity
profile across the solution domain is represented with a solid line at the post-processing locations.
Notice that Ansys Icepak creates a locally colored line according to the UY velocity magnitude,
seen in the graphics window.
Step 9: Summary
Figure 3.43: Variation Plot of UY Velocity Versus Z Coordinate
d. Save the X-Y plot.
i. Click the Save button at the bottom of the Variation of UY plot window.
ii. Enter a file name in the resulting Save curve dialog box.
iii. Click Save to save the file in the model folder.

In this tutorial, you have learned about the basic usage of enclosure, PCB, source and heat sink objects
to create an RF amplifier. You have also learned how to use Ansys Icepak’s fan library and search tool.
Furthermore, this tutorial has introduced you to evaluating mesh quality as well as non-conformal
meshing to reduce cell count and computational cost.
You have now learned the basic workflow of an Ansys Icepak project, including model building, mesh
generation, problem setup, solution calculation, and post-processing as well essential features and
functions that you will likely use in later tutorials or your own projects.
1. Best Practices
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a. Check the default materials, properties, and operating conditions under the Defaults tab in the
Basic parameters panel. These defaults often render some specifications unnecessary.
b. Use the alignment and morph tools to position objects based on other existing objects. This can
be faster than specifying object dimensions and coordinates in many situations.
c. Use the Show objects by type feature to verify your model objects by type.
d. View the HTML summary report (View Summary (HTML)) to ensure proper specification of
e. Reduce mesh counts and consequently decrease run times in regions requiring less resolution
by creating separately meshed assemblies when appropriate. Also select suitable slack values
that improve the convergence rate while avoiding mesh bleeding.
f. Select the Allow minimum gap changes option in the Misc tab of the Mesh control panel to
g. Ensure that you have at least three to four cells between fins to resolve adequately the boundary
layers between them by visually inspecting the mesh. Refine the mesh as necessary by using
Normal meshing.
h. Evaluate your mesh quality under the Quality tab in the Mesh control panel.
i. Use the Problem setup wizard for guided problem setup. Edit the problem setup if needed
j. Judge convergence by monitoring residual levels as well as relevant integrated quantities for
certain objects with point monitors, which should eventually stop changing significantly with
more iterations.
2. Tips and Tricks
a. Explore the several methods to complete a task as you work through a problem in Ansys Icepak.
For example, you can edit model object geometries by using their object edit panel, or you can
use the Edit window in the bottom right-hand corner while having the object node selected in
the Model manager window. Use the options best suited for you to help streamline your
workflow.
b. Cycle through all possible edges in the Morph edges mode by repeatedly clicking the left mouse
button. This is useful in case you have difficulty selecting an edge.
c. Remove object names by clicking the Display object names button ( ) to reduce visual clutter
in the graphics window.
d. Highlight critical regions using the Power and temperature limits feature (Model Power
and temperature limits) to designate maximum power and temperature, which can then be
highlighted in the graphics window after the solution calculation (Post Power and temper-
ature values). Note that setting these limits does not affect how Ansys Icepak calculates the
solution.
Step 9: Summary
e. Use the Reset button in the Basic settings panel to have Ansys Icepak estimate dimensionless
numbers (for example, the Reynolds and Peclet numbers for forced convection) and determine
the appropriate flow regime.
f. Hold your mouse pointer over any selection in the Problem setup wizard to have a text bubble
appear for additional information on the selection.
g. Use the Transparency slider in the post-processing object edit panels to improve visualization
of post-processing objects.
h. Move a plane cut through a model by pressing the Shift key, holding down the middle mouse
button on an edge of the plane cut and dragging the plane cut through the model in the
graphics window.
i. Expand all of your assemblies quickly by right-clicking Model in the Model manager window
then selecting Expand all.
Chapter 4: Use of Parameterization to Optimize Fan
Location
4.1. Introduction
The purpose of this tutorial is to demonstrate Ansys Icepak parametric and optimization features with
the help of a small system-level model.
In this tutorial, you will learn how to:
• Use network blocks as one way of modeling packages.
• Specify a contact resistance using side specifications of a block object.
• Define a variable as a parameter and solve the parametric trials to optimize your model for maximum
performance.
• Specify fan curves and dynamically update them.
• Use local coordinate systems.
• Generate a summary report for multiple parametric solutions.
The tutorial will guide you through the usual workflow with additional steps specific to this exercise:
creating a project, building the model, creating separately meshed assemblies, generating a mesh, setting
up parametric trials, creating point monitors, problem setup, calculating solutions, post-processing, as
well as an additional exercise to model the effects of higher altitude on the system.
Note:
4.2. Prerequisites
This tutorial assumes that you have little experience with Ansys Icepak, but that you are generally famil-
iar with the interface. If you are not, review Sample Session in the Icepak User’s Guide and the Finned
Heat Sink (p. 5) tutorial in this guide as some of the steps that were discussed in these tutorials will
not be repeated here.
Use of Parameterization to Optimize Fan Location

The system-level model consists of a series of IC chips on a PCB. A fan is used for forced convection
cooling of the power dissipating devices. A bonded fin extruded heat sink with eight 0.008 m thick fins
is attached to the IC chips. The fan flow rate is defined by a nonlinear fan curve. The system also consists
of a perforated thin grille. A study is carried out for the optimum location of the fan by using the
parameterization feature in Ansys Icepak.
Figure 4.1: Schematic of the Geometry

1. Start Ansys Icepak, as described in Starting Ansys Icepak in the Icepak User’s Guide.
3. Specify a name for your project (for example, fan_locations) and click Create.
Ansys Icepak creates a default cabinet with the dimensions 1 m 1 m 1 m, and displays the
cabinet in the graphics window. You will modify this cabinet in the next section.

1. Resize the default cabinet.
The cabinet forms the boundary of your computational model. Press the isometric view icon ( )
for a 3D view. Select Cabinet in the Model manager window and enter the location values as shown
in the geometry window below. The geometry window can be found in the lower right hand corner
of the GUI.
2. Create the Fan.
Click the Create fans icon ( ) in the object toolbar next to the Model manager window to create
a 2D intake circular fan on one side of the cabinet. Change the plane to yz and enter the location
values shown in the geometry window below:
• Defining a parameter for multiple trials.
One of the objectives of this exercise is to parameterize the location of the fan. To create a para-
metric variable in Ansys Icepak, input a $ sign followed by the variable name. Thus, to create the
parametric variable “zc”, type $zc in the zC box in addition to the other location values, and click
Apply. When Ansys Icepak asks you for an initial value of "zc", enter an initial value of 0.1, and
click Done.
Figure 4.2: The Param value Panel
We will now set the physical properties that will define the fan behavior:
a. Edit the fan object and go to Properties tab.
b. In the Properties tab, retain the selection of Intake for Fan type and select Non-linear in the
Fan flow tab.
c. Enter the characteristic curve by clicking on the Edit button and selecting Text Editor in the
drop-down list in the Non-linear curve group box.
Figure 4.3: The Fans Panel (Properties Tab)
d. First change the units of the volume flow rate and pressure according to the units in
Table 4.1: Values for the Curve Specification Panel (p. 106) and enter the values in pairs with a
space between them in the Curve specification panel.
Table 4.1: Values for the Curve Specification Panel
Volume Flow (CFM) Pressure (in_water)

0 0.42
20 0.28
40 0.2
60 0.14
80 0.04
90 0.0
Note:
Pay attention to the two zero values in Table 4.1: Values for the Curve Specification
Panel (p. 106). In general, you should start a fan curve specification with a zero flow
rate and end the specification with a zero pressure.
e. Click Accept to close the form.
f. Select the Edit button again in the Non-linear curve group box and click Graph Editor in the
drop-down list to view the fan curve (Figure 4.4: The Fan Curve Panel (p. 107) ).
Figure 4.4: The Fan Curve Panel
g. Click Done to close the Fan curve panel.
h. In the Properties tab under the Swirl tab, located next to the Fan flow tab, set the RPM of the
fan to 4000.
i. In the Properties tab, set the Operating RPM of 2000 in the Options tab, located next to the
Swirl tab.
Note:
The RPM under the Swirl tab specifies the nominal RPM of the fan from the existing
fan curve. The Operating RPM in the Options tab is a working RPM value used in
conjunction with the nominal RPM to dynamically scale and update the fan curve
according to the fan laws. The nominal RPM can also be used to compute the swirl
factor. Refer to Chapter 21: Fans in the User’s Guide for more information regarding
fan objects.
j. Click Update and Done to close the fan window.
Now the model looks as shown in Figure 4.5: Model with Fan (p. 108).
Figure 4.5: Model with Fan
Note:
The shading of the fan object can be changed by changing the Shading option under
the Info tab to change the shading of just that object, or by leaving it as default and
changing the default shading option by going to View Default shading to change
the shading of all objects that have default shading selected.
3. Set up a grille.
a. Click the Create grille icon ( ) for creating a new grille, set its plane to Y-Z. Then, using the
Morph faces ( ) option move the grille to the max-X face of the cabinet. After clicking the icon
( ), the graphics display window presents step by step instructions on how to use the Morph
faces option. Alternatively, you can use the coordinates shown in the geometry window below:
b. Now define properties for the grille by clicking the Properties tab.
Note:
This is a 50% open perforated thin grille.
i. For the Velocity loss coefficient, keep the default selection of Automatic.
ii. Specify a Free area ratio of 0.5.
Note:
The free area ratio is the ratio of the area through which the fluid can flow
unobstructed to the total planar area of the obstruction. Ansys Icepak calcu-
lates the loss coefficient of the grille based on the free area ratio. Different
resistance types govern the method of calculation. See Pressure Drop Calcu-
lations for Grilles in the User’s Guide for more information on the free area
ratio and the various pressure drop calculation methods.
iii. Retain Perforated thin vent for the Resistance type. Refer to Figure 4.6: Grille Panel (Prop-
erties Tab) (p. 110) for the correct settings.
Figure 4.6: Grille Panel (Properties Tab)
iv. Click Update and then Done to close the panel.
For more details on loss coefficient data, refer to Handbook of Hydraulic Resistance, by I. E. Idel'chik.
The model looks as shown in Figure 4.7: Model with Fan and Grille (p. 111).
Figure 4.7: Model with Fan and Grille
4. Set up a wall.
Note:
The model includes a 0.01 m thick PCB that touches and covers the entire min-Y floor
of the cabinet. The PCB is exposed to the outside with a known heat flux of 20 W/m2. In
order to consider the heat flux, we will use a wall object to simulate the PCB.
a. Click the Create walls icon ( ) to create a new wall. We will define the geometry and physical
parameters for the wall object:
i. Make the plane X-Z.
ii. Use the Morph faces icon ( ) from the model toolbar to align the wall object with the entire
min-Y floor of the cabinet.
Note:
If you have difficulty selecting faces, try clicking near the edge of a face. Clicking
correctly should highlight the entire face in red.
iii. Edit the Wall object and go to Properties tab.
iv. In the Material group box, set the Wall thickness to 0.01 m and the Solid material to FR-
4.
v. In the Thermal specification group box, specify a Heat flux of 20 W/m2. See Figure 4.8: Walls
Panel (Properties Tab) (p. 112) for the correct settings.
Figure 4.8: Walls Panel (Properties Tab)
vi. Click Update and then Done to close the panel.
After creating the wall, the model looks as shown in Figure 4.9: Model with Wall Added (p. 113).
Figure 4.9: Model with Wall Added
5. Create blocks.
In this step, you will create several types of blocks to represent different physics.
• Creation of Solid Blocks
Now, create four blocks that dissipate 5 W each and have a contact resistance of 0.005 C/W on
their bottom faces.
a. Create a new block ( ) , and retain the Type as solid and Geom as Prism. Enter the location
values shown in the panel below:
b. Edit the block and specify the following in the Properties tab:
i. In the Surface specification group box, click the Individual sides check box and click
Edit (Figure 4.10: The Individual side specification (p. 114)).
A. Select Min Y and toggle Thermal properties and Resistance.
B. Under Thermal condition, retain the selection of Fixed heat and Total power of 0
W.
C. Select Thermal resistance from the drop-down menu next to Resistance.
D. Set Thermal resistance to 0.005 C/W.
E. Click Accept to close the panel.
Figure 4.10: The Individual side specification
ii. In the Thermal specification group box in the Properties tab, retain the selection of de-
fault for Solid Material (you can also select Al-Extruded which is the default).
iii. Set Total Power to 5 W.
iv. Click Update and Done to close the panel.
c. Next, make three copies of this block with an X offset of 0.08 m.
Note:
The previous tutorial showed you how to make a copy of an object.
Figure 4.11: Creation of Solid Blocks
• Creation of Network blocks
Create four IC chips in the form of network blocks. To create a network block, create a Block object
and change the block type to Network in the Properties tab. Each network block has junction-
to-board, junction-to-case, and junction-to-sides thermal resistances. The values of these resistances
are known beforehand.
a. Add a new block, and position it as shown in the panel below:
b. Edit the block to change the properties of this block:
– Ensure that the Block type is set to Network.
– Toggle Star Network.
→ Enter the Network parameters as shown in Figure 4.12: The Properties Panel (p. 116).
Figure 4.12: The Properties Panel
c. Now make three copies of this network block with an X offset of 0.08 m. This finishes the
creation of the network blocks.
• Creation of a Hollow Block
Note:
Finally, to cut out a section of the cabinet from the computational domain, create a
hollow block. This represents a region that does not directly affect heat transfer via
solid conduction but that does, however, alter the flow patterns surrounding this region.
a. Create a new Block. Set the Block type as Hollow.
b. In the Geometry tab, go to the Local coord system drop-down menu.
c. Select Create new to open the Local coords panel.
d. Enter X offset = 0.1, Y offset = 0, Z offset = 0.
e. Click Accept. This is just to demonstrate the use of local coordinate system.
f. Further, size the block as follows:
6. Now we will create the detailed heat sink. The heat sink base acts as a heat spreader for all the
chips.
a. Click the Create heat sinks icon ( ) and edit it. In the Properties tab, select Detailed in the
Type drop-down menu. Entering its location and properties as shown in the following table:
Table 4.2: Heatsink Properties
Geometry
Plane: X-Z
xS / xE: 0.05/0.34
yS / yE: 0.03/—
zS / zE: 0.1/0.23
Base height: 0.01 m
Overall height: 0.06 m
Properties
Type: Detailed
Flow Direction: X
Detailed Fin type: Bonded fin
Fin setup
Fin spec: Count/thickness
Count: 8
Thickness: 0.008 m
Flow/thermal data
Fin material: default
Base material: Cu-Pure
Interface
Fin bonding: Click the Edit button

Effective thickness: 0.0002 m
Solid material: default
b. Click Update and Done. This completes the model building process. The complete model should
look like that shown in Figure 4.13: Final Model (p. 118).
Figure 4.13: Final Model
7. Check the definition of the modeling objects to ensure that you have specified them properly.
View Summary (HTML)
The summary report now appears in a web browser. The summary displays a list of all the objects
in the model and all the parameters that have been set for each object. You can view the detailed
version of the summary by clicking the appropriate object names or property specifications. If you
notice any incorrect specifications, you can return to the appropriate modeling object panel and
change the settings in the same way that you originally entered them.
Note:
The summary report also shows the user-specified material properties for each of
the objects to help identify the proper material specifications. Figure 4.14: Partial
Step 3: Creating Separately Meshed Assemblies
Table of Summary Report for Blocks (p. 119) shows the summary report for block.1,
which includes its material specifications.
Figure 4.14: Partial Table of Summary Report for Blocks
4.6. Step 3: Creating Separately Meshed Assemblies

One of the key aspects of modeling is to use a mesh with good quality and sufficient resolution for the
model. We need to have a fine mesh in the areas where temperature gradients are high or flow is
turning. Having too coarse of a mesh will not give you accurate results and having too fine a mesh may
lead to longer run times. The best option is to explore the model carefully and look for opportunities
to reduce mesh counts in the areas where the gradients are not steep. Creating non-conformal assemblies
gives required accuracy along with reduced mesh count. Select a set of objects to create assemblies.
Also decide suitable slack values for assembly bounding box. Your selection can be reviewed in the
section below where we will create non-conformal meshed assemblies.
We will now create two non-conformal meshed assemblies.
1. To create the first assembly, first highlight all the blocks (except the hollow block) and the heat sink
object in the Model manager window, then right-click them and choose Create and then Assembly.
2. Right-click and select Rename from the menu. Rename the assembly, as Heatsink-packages-asy.
3. To build the "bounding box" for the assembly called Heatsink-packages-asy, double-click it to edit
the assembly.
4. In the Meshing tab of the Assemblies panel, toggle Mesh separately, and then set the Slack
parameters as the following:
Table 4.3: Slack Values for Heatsink-packages-asy Assembly
Min X 0.005 m Max X 0.015 m

Min Y 0.005 m Max Y 0.005 m
Min Z 0.005 m Max Z 0.005 m
Note:
• Note that for the Heatsink-packages-asy, we have set a bounding box that is 0.005 m
bigger than the assembly at five sides except Max X where the slack is defined higher
(0.015 m) to capture the wake region of the flow.
5. Click Update and Done to complete the bounding box specifications for the assembly.
Following the same procedure above, create one more assembly for the fan object (name it Fan-
asy). Use the following table to assign the Slack values for the Fan-asy assembly.
Table 4.4: Slack Values for Fan-asy Assembly
Min X 0m Max X 0.005 m

Min Y 0.002 m Max Y 0.002 m
Min Z 0.002 m Max Z 0.002 m

To generate the mesh:
1. Open the Mesh control panel, keep the default values for the mesh settings and ensure that Mesh
assemblies separately is selected.
2. Click Generate. You may get a warning about minimum separation if the Allow minimum gap
changes option is deselected in the Misc tab.
Note:
This warning appears because the Minimum gap (separation), which is like a tolerance
setting for the mesher, is larger than 10% of the smallest feature in the model. When
there are objects smaller than the mesher tolerance, those objects will not be meshed
correctly. To avoid this, you need to change the value to modify the minimum gap to
10% of the smallest object. The prompt window that appears allows you to do this with
the Change value and mesh option. This option is used for this particular tutorial and
may not be applicable all the time. As the mesh separation setting is a useful tool designed
to avoid unnecessary meshing due to inadvertent misalignments in the model (without
modifying the geometry), we may use other options suitable to the model.
3. Click Change value and mesh.
4. Examine the mesh by taking plane cuts in all directions under the Display tab.
5. Go to the Mesh control panel, click the Quality tab and examine Face alignment (Figure 4.15: Graph
of Face alignment (p. 121)). Due to differences among different machines, your numbers may not be
exactly the same as those of Figure 4.15: Graph of Face alignment (p. 121).
Figure 4.15: Graph of Face alignment
Note:
Recall from previous examples that Figure 4.15: Graph of Face alignment (p. 121) is a graph
of cell number versus face alignment. For more information on face alignment as a
measure of mesh quality, see Checking the Face Alignment from the Icepak User’s Guide.
6. Click Close when you are done.
4.8. Step 5: Setting up the Multiple Trials

Before we start solving the model, we will set up the parametric trials for the fan location parameter
"zc".
1. Go to the Solve menu and select Define trials.
a. The Parameters and optimization panel pops up.
b. Toggle Parametric trials in the Setup tab.
c. Select the Design variables tab and next to Discrete values, type 0.165 following 0.1, separ-
ated by a space as shown in the Figure 4.16: The Parameters and optimization Panel (Design
variables Tab) (p. 122):
Figure 4.16: The Parameters and optimization Panel (Design variables Tab)
Step 5: Setting up the Multiple Trials
d. Click Apply.
Note:
After the first trial has been completed, Ansys Icepak has the option of starting the fol-
lowing trial(s) from the default initial conditions specified in Problem setup panel, or
from the solution(s) of the trial run(s) that have completed.
For this model, next go to the Trials tab and ensure the Restart ID is blank for the 2nd trial as
shown in Figure 4.17: The Parameters and optimization Panel (Trials Tab) (p. 124). This instructs Ansys
Icepak to start the 2nd run from the default initial conditions.
2. Click Reset button and select Values to use the base names for trial naming. Note that resetting
automatically selects tr_zc_0_1 for the second trial’s Restart ID. Delete this entry to make it blank
again.
Figure 4.17: The Parameters and optimization Panel (Trials Tab)
3. Click Done to close the Parameters and optimization panel.
4.9. Step 6: Creating Monitor Points

Create two monitor points by dragging and dropping (block.1 and grille.1) into the Points folder to
monitor the velocity in the grille and the temperature in one of the solid blocks. You can easily change
the variables monitored by selecting them in the Modify points panel. Select Velocity for the grille
and Temperature for the block.
Step 7: Physical and Numerical Setting
Figure 4.18: The Modify point Panel
4.10. Step 7: Physical and Numerical Setting

First, use the Basic settings panel to determine the flow regime.
1. Enter 200 in the Number of iterations field in the Basic settings panel (Figure 4.19: The Basic settings
Panel (p. 125)).
Figure 4.19: The Basic settings Panel
2. Click Reset. In the message window. Ansys Icepak recommends setting the flow regime to turbulent
based on the approximate Reynolds and Peclet numbers.
3. Click Accept to accept the new settings.
Use the Problem setup wizard to set up the basic parameters of the problem.
1. Right-click Problem setup in the Model manager window and select Problem setup wizard.
2. Follow the instructions as the Problem setup wizard panel guides you.
Important:
Do the following in the wizard (keep the rest of the settings at default): Select forced
convection, set the flow regime to turbulent, use the zero equation turbulence model,
include radiation heat transfer, and use the surface-to-surface radiation model.
3. Click Done when the panel is at step 14 of 14 to finish your problem setup.
Note:
You can edit the problem setup by expanding Problem setup in the Model manager
window, then double-clicking Basic parameters ( ). Figure 4.20: The Basic parameters
Panel (p. 127) shows the panel that appears.
Figure 4.20: The Basic parameters Panel

Ansys Icepak saves the model for you automatically before it starts the calculation, but it is a good idea
File Save project
Alternatively, click the save button ( ) in the file commands toolbar.

Solve Run solution
In the Results tab of the Solve panel that appears, enable Write overview of results when finished,
then click Dismiss to close the Solve panel. The Solve panel is used for single trials only; therefore, the
solution can only be calculated from the Parameters and optimization panel.
Solve Run optimization
In the Parameters and optimization panel that appears (Figure 4.17: The Parameters and optimization
Panel (Trials Tab) (p. 124)), click Run to calculate a solution for both trials.

Once the solutions converge, load the solution ID:
Post Load solution ID
Select the solution that corresponds to the first (parametric) run: zC = 0.1. Use the various post-processing
features available in Ansys Icepak to display your solution. A description of how to generate plane cut
and object face views can be found in Step 7: Examine the Results (p. 36) of the Finned Heat Sink tu-
torial. In particular, use the following views:
1. Plane cut panel to display the velocity vectors on a plane through the cabinet
Figure 4.21: Trial 1 Vector Plots at Constant Z Plane Cut
Figure 4.22: Trial 2 Vector Plots at Constant Z Plane Cut
Important:
To view the 2nd parametric run, click the Post menu and select Load solution ID.
Select the solution that corresponds to the second parametric run: zC = 0.165. The
graphics display window updates automatically.
2. Object face panel to display temperature contours on wall.1 and on all blocks
Figure 4.23: Trial 1 Temperature Contours on Blocks and PCB (wall.1)
Figure 4.24: Trial 2 Temperature Contours on Blocks and PCB (wall.1)
3. Surface probe panel to display the temperature values at a particular point
Examine the solution sets of both runs. You will find that, in the second run, the maximum temper-
ature is lower than in the first run and that the network blocks are the hottest objects inside the
cabinet. The second trial has the fan located at zC= 0.165 which is closer to the heat sink location.
This increases the flow velocity over the heat sinks and thus increases the convective heat transfer
coefficient, which leads to more heat transfer from the fins (blocks) and thus reduces the maximum
temperature.
4.14. Step 11: Reports

1. Overview Report
At the end of the runs, Ansys Icepak automatically displays an overview report because you selected
Write overview of results when finished in the Solve panel. This report has:
• fan operating point
• volume flow rate through the grille
• heat flow from the chips
• network junction temperatures
• heat flows for the wall and the grille.
Examine these results. Go to the Report menu and then select Solution overview and click View
to display the desired overview report.
2. Summary Report
Step 12: Summary
You can also create a single summary report containing the results of all the trial runs completed.
Go to the Solve menu and select Define report. In the Define summary report panel, under ID
pattern, enter the default filter, "*", which selects all the available solution IDs. Click New and then
hold down Ctrl. Select block.1, block.1.1., block.2, block.2.1, and block.3 from the
drop-down menu under Objects, click Accept and then click Write. Verify that the second trial gives
lower maximum and mean temperatures.

In this tutorial, you learned how to set up and solve multiple trials to optimize a parameter, specify a
dynamically updating fan curve, create a new local coordinate system, and use separate meshed assem-
blies to reduce mesh counts. The use of network blocks to model packages has been demonstrated as
well as how to specify contact resistance using side specifications of a block object. You also learned
how to generate a summary report for multiple solutions.
1. Best Practices
a. Start a fan curve specification with a zero flow rate and end the specification with a zero pressure.
b. View the HTML summary report (View Summary (HTML)) to ensure proper specification of
c. Reduce mesh counts and consequently decrease run times in regions requiring less resolution
d. Select the Allow minimum gap changes option in the Misc tab of the Mesh control panel to
e. Create monitor points of relevant quantities (temperature, pressure, or velocity) to help judge
convergence alongside residuals.
f. Use the Problem setup wizard for guided problem setup. Edit the problem setup if needed
2. Tips and Tricks
a. Use the RPM under the Swirl tab as a fan's nominal RPM. Use the Operating RPM in the Options
tab as the working RPM value, used in conjunction with the nominal RPM to update the fan
curve according to the fan laws.
b. Display different types of shading to help visualize parts of your model better by editing an in-
dividual object in the Model manager window or by applying it globally (View Default
shading).
c. Click near the edge of a face in the Morph faces mode if you have difficulty selecting faces.
Clicking correctly should highlight the entire face in a red shading.
Note:
Use the left mouse button first to select a face, then accept the selection with the
middle mouse button. Right-click to cancel your selection or to exit the Morph faces
mode.
d. Create hollow blocks to cut out a section of the cabinet from the computational domain. Hollow
blocks only alter flow patterns and do not participate in solid conduction heat transfer.
e. Use the appropriate Restart ID for your trials' initial conditions when running a parametric op-
timization to improve convergence rate.
4.16. Step 13: Additional Exercise to Model Higher Altitude Effect

You can also use the final model to simulate the effects of higher altitudes. In order to model this cor-
rectly, new air properties at the particular altitude need to be defined and assigned to the default fluid.
The density of air is the most affected property and gets lower as altitude increases. The data for air
properties at a different altitude is presented in many handbooks and may even include temperature
change with it. For an altitude of 3000 m, you can select the available library material Air@(3000m).
Note that you can create and store a custom material having any properties in the material library for
use in any project.
In the Model manager window, select Problem setup Basic parameters and assign the new
air material to be the default fluid.
Step 13: Additional Exercise to Model Higher Altitude Effect
On the Advanced tab under Altitude effects, select Altitude and enter 3000 m. Then select Update
fan curves to automatically update fan curves to account for altitude effects.
Chapter 5: Cold-Plate Model with Non-Conformal
Meshing
5.1. Introduction
This tutorial demonstrates how to model a cold-plate using Ansys Icepak.
• Use the meshing priorities of different objects to mesh complicated model setups in Ansys Icepak.
• Use multiple fluids in a single model.
• Account for external natural convection and internal forced convection.
• Create separately meshed assemblies to reduce the overall mesh count.
• Specify per-object meshing parameters.
Note:
5.2. Prerequisites
This tutorial assumes that you have reviewed Sample Session in the Icepak User’s Guide and tutorials
Finned Heat Sink (p. 5) and RF Amplifier (p. 51) of this guide.

The model consists of a cold-plate, where the cold-plate fluid is transporting a significant fraction of
the heat from two plates mounted on either side of it. The natural convection in the external air is also
instrumental to heat transfer in this case. The model setup is shown in Figure 5.1: The Cold-Plate Mod-
el (p. 136).
Cold-Plate Model with Non-Conformal Meshing
Figure 5.1: The Cold-Plate Model
The objective of this exercise is to illustrate the use of two different fluids in Ansys Icepak. The model
includes two heated plates, cooled by water circulating inside the cold-plate cavity, as well as by air
driven by natural convection externally. Separately meshed assemblies will be employed to reduce the
overall mesh count in the domain. The model will be constructed using the default metric unit system.

Create a new project called cold-plate.

Construct the cabinet and all the other objects according to the following specifications. Note that
during the model building, you may use the alignment tools. Remember that you can align the face,
edge and vertex of one object with another. For example, you could align the bottom face of the cylinders
to the cabinet (see Figure 5.1: The Cold-Plate Model (p. 136)). You may also use the align tools to create
the openings on the cold-plate inlet and outlet regions.
• Cabinet ( )
Enter the following start and end locations for the cabinet:
Table 5.1: Cabinet Start and End Values
xS 0.0 m xE 0.4 m
yS 0.0 m yE 0.3 m
zS 0.0 m zE 0.2 m
• Blocks ( )
Create a solid block, block.1, and a fluid block, block.2, with the specifications in Table 5.2: Specific-
ations of block.1 and block.2 (p. 137). Note the specified materials for each block.
Table 5.2: Specifications of block.1 and block.2
Object
Name: block.1 xS 0.05 m xE 0.35 m
Geometry: Prism yS 0.08 m yE 0.22 m
Block type: Solid zS 0.07 m zE 0.13 m
Solid material:
Al-Extruded
Name: block.2 xS 0.06 m xE 0.34 m

Geometry: Prism yS 0.09 m yE 0.21 m
Block type: Fluid zS 0.08 m zE 0.12 m
Fluid material:
Water(@280K)
Because you have created block.2 after block.1, block.2 has a higher relative meshing priority.
Note:
Ansys Icepak meshes the objects according to their mesh priority; this is important when
intersection between two or more objects occurs. If two or more objects intersect, you
may not obtain the correct results with the default meshing priority. The ascending order
of the model object nodes in the model manager window determines the mesh priority
of the corresponding model objects. For example, the model object in the bottom node
has the highest meshing priority. For more information on controlling meshing priority,
see Controlling the Meshing Order for Objects in the Ansys Icepak User’s Guide.
Note:
Because Al-Extruded is set as the Default solid in the Defaults tab of the Basic paramet-
ers panel, you can leave the material selection as default while creating the object instead
of selecting the material each time when an object is being created.
Next, create 4 cylindrical blocks. While editing cylindrical blocks, first select the block shape as cylinder,
then select the desired plane and finally enter the dimensions.
Table 5.3: Cylindrical Block Specifications
Object xC yC zC Height Radius IRadius Specifications

Name: 0.1 0.0 0.1 0.09 0.015 0.0 m Block type: Solid
block.3 m m m m m
Geometry: Solid material: Al-Extruded
Cylinder
Plane: X-Z
Name: 0.3 0.0 0.1 0.09 0.015 0.0 m Block type: Solid
block.4 m m m m m
Geometry: Solid material: Al-Extruded
Cylinder
Plane: X-Z
Name: 0.1 0.0 0.1 0.09 0.01 0.0 m Block type: Fluid
block.5 m m m m m
Geometry: Fluid material: Water(@280K)
Cylinder
Plane: X-Z
Name: 0.3 0.0 0.1 0.09 0.01 0.0 m Block type: Fluid
block.6 m m m m m
Geometry: Fluid material: Water(@280K)
Cylinder
Plane: X-Z
Because the fluid blocks, block.5 and block.6, are created after the solid blocks, they will have
higher relative meshing priorities.
Note:
An alternative way to build the cylinders would be to create the solid block, block.3, and
then the fluid block, block.5, group these together, and then copy them with an offset of
0.2 in the X direction. Note that the naming of the cylinders will not be consistent with
the tutorial. However, you could rename the objects to their corresponding names in the
tutorial by right-clicking each copied object in the Model manager window and selecting
Rename.
• Plates ( )
Table 5.4: Plate Specifications
Object Specifications
Name: plate.1 xS 0.07 m xE 0.33 m Thermal model:
Conducting thick
(0.01 m)
Geometry: yS 0.1 m yE 0.2 m Total power:
Rectangular 200 W
Plane: X-Y zS 0.06 m zE —
Solid materi-
al: Al-Extruded
Name: plate.2 xS 0.07 m xE 0.33 m Thermal model:

Conducting thick
(0.01 m)
Geometry: yS 0.1 m yE 0.2 m Total power:
Rectangular 200 W
Plane: X-Y zS 0.13 m zE —
Solid materi-
al: Al-Extruded
Note:
An alternative way to create plate.2 is to copy plate.1 with a Z offset of 0.07 m.
• Openings ( )
The openings at the liquid inflow and outflow regions of the cold-plate are:
Table 5.5: Opening Specifications
Object xC yC zC Radius Specifications

Name: opening.1 0.1 m 0m 0.1 m 0.01 m
(outlet opening)
Type: Free
Geometry:
Circular
Plane: X-Z
Name: opening.2 0.3 m 0m 0.1 m 0.01 m Y Velocity = 0.2

(inlet opening) m/s
Type: Free
Geometry:
Circular
Plane: X-Z
Note:
You could also have made a copy of the outlet opening (opening.1) with an X offset of
0.2 m along with a specified Y Velocity = 0.2 m/s to create the inlet opening (opening.2).
For agreement with the tutorial, ensure that you have placed the inlet and outlet in their
correct positions by referring to Figure 5.1: The Cold-Plate Model (p. 136).
The openings at the cabinet boundary for external air natural convection are:
Table 5.6: Openings at Cabinet Boundary Specifications
Object
Name: opening.3 xS 0.4 m xE —
Type: Free yS 0.0 m yE 0.3 m
Geometry: zS 0.2 m zE 0.0 m
Rectangular
Plane: Y-Z
Name: opening.4 xS 0.0 m xE —

Type: Free yS 0.0 m yE 0.3 m
Geometry: zS 0.2 m zE 0.0 m
Rectangular
Plane: Y-Z
Note:
Instead of creating the openings, opening.3 and opening.4 above, you could have edited
Cabinet and changed the wall type on the Min x and Max x faces to Opening. Note,
however, that you cannot rename the two resulting objects.
See Figure 5.1: The Cold-Plate Model (p. 136) for the final model.
Note:
Figure 5.1: The Cold-Plate Model (p. 136) displays different opacity, shading and color of
some objects to make the objects easier to see.
Step 3: Create a Separately Meshed Assembly
5.6. Step 3: Create a Separately Meshed Assembly

To create a separately meshed assembly, highlight all the objects in the Model manager window except
the cabinet, opening.3, and opening.4. Right-click them and choose Create and then Assembly. To
enable separate meshing for the assembly, double-click assembly.1 to edit the assembly. Under the
Meshing tab, toggle the Mesh separately button and then enter the slack values as follows in the
Slack settings box:
The bounding box of the assembly is larger than the original assembly by 0.01 m on five sides. The
slack value for the min Y side of the assembly is set to be 0 m, since the min Y side of the assembly is
at the bottom surface of the cabinet. Click Update and Done to complete editing the separately meshed
assembly.

Open the Mesh control panel and ensure that your settings match those of Figure 5.2: Mesh control
Panel Settings (p. 143). The mesh needs to be refined for the inner prismatic fluid block (block.2). In the
Misc tab, use the settings shown in the below figure. Then toggle Object params and click Edit in the
Local tab. Choose block.2 and check Use per-object parameters and enter 30, 16, and 10 respectively
for the X, Y, and Z counts for the mesh in the fluid block, as shown in the following figure. Click Done
to close the Per-object meshing parameters panel.
Note:
The X, Y, and Z "counts" are also known as element counts, the number of divisions into
which an edge is subdivided. In other words, an element count is the number of elements
that lie along the edge. For more information on per-object meshing parameters, see
Definitions of Object-Specific Meshing Parameters in the Ansys Icepak User’s Guide.
Figure 5.2: Mesh control Panel Settings
Click Generate to mesh the model. Visualize the mesh at plane cuts and surface displays from the
Display tab. Note that if you have Selected object selected, you can only generate surface and volume
mesh displays on the objects themselves and not an assembly. You may select several objects in order
for several concurrent displays or you may select All to generate mesh displays for all objects automat-
ically.

Calculation of the Reynolds number based on properties of Water(@280K) and the inlet opening dia-
meter shows that the problem is turbulent.
Caution:
Using the Reset button in the Basic settings panel to determine flow regime will give
dimensionless numbers based on the default fluid material from the Basic parameters
panel, which in this case is Air. Therefore, exercise caution when relying on Ansys Icepak
to determine the Reynolds number.
Note:
Instead of accessing the Basic parameters panel, you can instead use the Problem setup
wizard to define your problem setup by double-clicking Problem setup in the Model
manager window. See Step 4: Physical and Numerical Settings (p. 28) in the Icepak Tutorials
of the Finned Heat Sink tutorial for more instruction regarding the Problem setup wizard.
You must still use the same settings described in this tutorial for the Problem setup wizard.
To set up turbulent flow, go to Problem setup Basic parameters and choose the Zero
equation turbulence model for the Flow regime in the General setup tab.
Gravity acts in the negative x direction in this problem. To setup the effects of gravity, toggle the
Gravity vector in the General setup tab. Enter the new values for the Gravity vector as X = -9.80665
m/s2, Y = 0.0 m/s2, and Z = 0.0 m/s2. Now go to the Transient setup tab and set an initial X velocity
of 0.005 m/s in the X direction. Accept all other defaults in the Basic parameters panel. These are
shown in Figure 5.3: Switching on Gravity and Turbulent Flow (p. 145).
Figure 5.3: Switching on Gravity and Turbulent Flow
Note:
For steady-state natural convection cases, set a small initial velocity opposite to the gravity
vector direction as this assists with the initial convergence of the model. For cases in which
there is no forced convection, clicking on Reset in the Solution settings Basic
settings menu automatically sets a small initial velocity in the direction opposite to the
gravity vector. This may not be necessary in this model though, because the flow will be
forced through the cold plate. We will have mixed (forced and natural) convection heat
transfer.
Figure 5.4: Basic and Advanced Solver Settings
Select the Basic settings panel from the Solution settings branch of the tree and set the Number of
iterations to 300. Go to Advanced settings and make sure Under-relaxation factors for Pressure,
Momentum, and Temperature are 0.3, 0.7, and 1.0, respectively. Change the Stabilization under
Joule heating potential to BCGSTAB, and select Double for the Precision drop-down list. The recom-
mended basic settings and advanced solver setup for this model are shown in Figure 5.4: Basic and
Advanced Solver Settings (p. 146).
Add three monitor points to the Points folder, one to monitor the velocity at the center of the opening.1
(outlet opening), and two to monitor the temperature at the center of block.2 and plate.2, respectively.
The easiest way to create them is to select the objects from the Model manager window and then
drag them to the Points folder of the tree. Ansys Icepak will then automatically monitor values at the
centers of these objects. The default setting is to monitor Temperature. To change this, double-click
the object under the Points folder and choose which variables to monitor at that location.

to save the model after the model building and meshing is complete.
File Save project
Alternatively, click the save button ( ) in the file commands toolbar.

Select the Solve menu and click Run solution. In the Solve panel, under the Results tab toggle Write
overview of results when finished, and then click Start solution.

Review the solution overview report created to ensure that mass (volume) flow rate and energy balances
are satisfied. To postprocess the results, create the following object face and plane cut objects:
Table 5.7: Object Face and Plane Cut Specifications
Object Specifications/Display Attributes Description

face.1 Object: all blocks (select the blocks using Object-face view of temperature on all the blocks.
the Ctrl key or the Shift key and the left What is the maximum temperature?
mouse button)
Show contours/Parameters
Contours of: Temperature
Contours options: Solid fill and
Smooth
Color levels: Calculated/Global limits
cut.1 Set position: Z plane through center Observation: Water is circulating through the internal
Show vectors/ Parameters channel, providing most of the cooling for the
Color by: Velocity Magnitude model. On the outside, air flows over the system by
Color levels: Calculated/Global limits natural convection.
face.2 Objects: opening.1 (outlet) and open- Observe the flow pattern from inlet opening to
ing.2 (inlet) outlet opening passing through the cold plate.
Show particle traces/ Parameters Animate the particle traces.
Variable: Speed
Display options: Uniform: 30
Particle options: Keep all the defaults
Style: Trail (Width = 1) and
Marker: (cone )
Color levels: Calculated/ This Object
cut.2 Set position: X plane through center Observe the flow pattern in positive X direction.
Show particle traces/ Parameters Animate the particle traces.
Color variable: Speed
Display options: Uniform: 30
Particle options: Keep all the defaults
Style: Trail (Width = 1) and
Marker (cone )
Color levels: Calculated/ This Object
cut.3 Set position: Y plane through center Due to the nature of the problem, the temperature
Show contours of Temperature. distribution is symmetric on the Y-Z plane. Verify
this in the solution.
You can save the post-processing objects that you just created by clicking Save post objects to file
option in the Post menu. Ansys Icepak will save these objects under the file named post_objects in
the Icepak project folder.

In this problem, you modeled a cold-plate that included two heat plates cooled by water circulating
inside the cold-plate cavity as well as air driven by natural convection externally. This exercise has also
demonstrated how to use the different meshing priorities of objects to model complicated model setups,
model multiple fluids in a single model, account for external natural convection and internal forced
convection, create separately meshed assemblies to reduce the overall mesh count, and specify per-
object meshing parameters.
1. Best Practices
a. Use the alignment and morph tools to position objects based on other existing objects. This can
be faster than specifying object dimensions and coordinates in many situations.
Step 10: Additional Exercise
b. Reduce mesh counts and consequently decrease run times in regions requiring less resolution
c. Use the Problem setup wizard for guided problem setup. Edit the problem setup if needed
d. Create monitor points of relevant quantities (temperature, pressure, or velocity) to help judge
2. Tips and Tricks
a. Copy similar objects then edit the copied objects to the desired specifications to eliminate re-
dundancies. This may be faster than creating every object individually.
b. Display different types of shading to help visualize parts of your model better by editing an in-
dividual object in the Model manager window or by applying it globally (View Default
shading).
c. Exercise caution when using the Reset button in the Basic settings panel to determine the
flow regime. Ansys Icepak only provides estimates, which may not necessarily be the correct
value for your application. In some cases, you may want to perform a hand calculation to confirm.

To see the cooling capacity or effectiveness of water, run the same model by replacing the fluid mater-
ial of the fluid blocks with Glycol-20; that is, change all the water blocks into glycol blocks. You should
see an increase in the maximum global temperature. Note that this fluid material is actually ethylene
glycol.
Chapter 6: Heat-Pipe Modeling and Nested
Non-Conformal Meshing
6.1. Introduction
This tutorial demonstrates how to model simple heat pipes and an active heat sink using Ansys Icepak.
• Create orthotropic solid materials.
• Use those materials to simulate a simplified heat-pipe in a system.
• Use of copy mirror and copy translate functions to create an array of objects.
• Create nested non-conformal assemblies.
Note:
6.2. Prerequisites
This tutorial assumes that you have little experience with Ansys Icepak, but that you are generally famil-
iar with the interface. If you are not, review Sample Session in the Icepak User’s Guide and the tutorial
Finned Heat Sink (p. 5) of this guide. Some steps in the setup and solution procedure will not be
shown explicitly.

Heat-pipes are used to transport heat from a heat source area, where there is limited space for heat
dissipation, to a place where it can be dissipated more easily. The objective of this exercise is not to
model the detailed physics inside a heat pipe. Instead, you will model a heat pipe by using a series of
cylindrical solid blocks that connect the heat source to an air-cooled heat sink. These blocks will have
an orthotropic conductivity with a very large conductivity in the pipe axis direction along which the
heat is carried away. The model will be constructed using the default metric unit system. You will also
make use of nested non-conformal meshing using assemblies to reduce the cell count in the model.
Heat-Pipe Modeling and Nested Non-Conformal Meshing
Figure 6.1: Heat-pipe Tutorial Base Model

1. Set up a working directory on the computer you will be using.
2. Download the heat_pipe.zip file here.
3. Unzip the heat_pipe.zip file you have downloaded to your working directory.
4. Copy the file heat-pipe-nested-NC.tzr to your working directory.
Note:
Ansys Icepak can be started in Ansys Workbench using the import .tzr feature or it can
be opened as a stand-alone product.
6. Click Unpack in the Welcome to Icepak panel.
7. In the File selection panel, select the packed project file heat-pipe-nested-NC.tzr and click
Open.
8. In the Location for the unpacked project file selection dialog, select a directory where you would
like to place the packed project file, enter a project name in the New project text field, then click
Unpack.
Note:
In Ansys Icepak, the packed file feature compresses a model to the files needed to build,
mesh and run the model (job, model, and problem files). In many of the tutorials, part of the
model is already created and packed to speed up the learning process. The model originally
has three blocks and only block.1 has an assigned power (25 W). The model also has one
fan and one grille. Next, build a heat sink in the area of the fan, grille and the heat pipe
system to connect block.1 to the heat sink.
1. Create materials utilizing Ansys Icepak’s orthotropic material conductivity feature. The idea is to
have a material that has very high conductivity in the pipe heat removal directions but normal
conductivity in the other directions.
• Click the material icon ( ) in the object toolbar for each new material to be created.
• Right-click the material name and select Edit or double-click the material name to open the Edit
panel.
• Go to the Properties tab and make sure to toggle Material type to be Solid and set the Con-
ductivity type to be Orthotropic from the drop-down list.
• Deselect the Edit check box next to Conductivity and create the following materials with ortho-
tropic conductivity properties using the template in Figure 6.2: Orthotropic Material Proper-
ties (p. 154).
Figure 6.2: Orthotropic Material Properties
Table 6.1: Orthotropic Properties
Name Nominal Con- Orthotropic multiplier

ductivity
material.1 20000 X=1 Y = 0.005 Z = 0.005
material.2 20000 X = 0.005 Y=1 Z = 0.005
material.3 20000 X=1 Y=1 Z = 0.005
The above materials have “orthotropic conductivity”, which means conductivity is different per
orthogonal direction. The effective conductivity in each orthogonal direction is equal to the
nominal conductivity multiplied by the orthotropic multiplier in that direction.
2. After creating these heat pipe materials, we build the heat pipe made of cylindrical blocks and
square joints.
• Create five block objects.
• Use the values in the following table (be sure to note the geometry)
Table 6.2: Block Specifications
Object Geometry xC yC zC Height Radius IRadius Specifications

pipe1 Shape: 0.05 0.11 0.1 0.245 0.01 m 0.0 m Type: solid
Cylinder m m m m
Plane: Solid material:
Y-Z material.1
Cylinder m m m m
Y-Z material.1
Cylinder m m m m
X-Z material.2
Object Geo- xS yS zS xE yE zE Specifications

metry
Joint1 Shape: 0.295 0.095 0.085 0.325 0.125 0.115 Type: solid
Prism m m m m m m
Solid material:
material.3
Joint2 Shape: 0.295 0.35 0.085 0.325 0.38 m 0.115 Type: solid
Prism m m m m m
Solid material:
material.3
Note:
You can use the Copy object function to speed up the creation of the remaining objects
after pipe1 and joint1 are created. However, the names will not be the same as the
tutorial. To rename an object, right-click the object in the Model manager window
and click Rename.
3. Next, we will also build the heat sink using block objects.
• Build the base and one pin according to the following
Table 6.3: Base and Pin Specifications
Ob- Geometry xS yS zS xE yE zE Properties

ject
Base Shape: 0.42 0.35 0.05 0.592 0.38 m 0.15 m Type: solid
Prism m m m m
Solid material:
default
Ob- Geometry xC yC zC Height Radius IRadius Properties

ject / Radi- / IRadi-
us2 us2
Pin Shape: 0.44 0.38 0.067 0.04 0.01 m 0m/0 Type: solid
Cylinder m m m m / m
0.006
m
Plane: X-Z Solid material:
default
Nonuni-
form
selected
(for a
nonuniform
radius)
Note that the Nonuniform check box is available in the Edit window. Alternatively, you may find
it also named Nonuniform radius in the Geometry tab of the Blocks panel as shown below. The
Plane option is X-Z (Figure 6.3: Nonuniform Cylinder (p. 157)).
Figure 6.3: Nonuniform Cylinder
• Make two copies of Pin with an offset of 0.033 m in the Z direction (Number of copies = 2,
Translate with Z offset = 0.033 m).
• Highlight the three tapered fins (Pin, Pin.1 and Pin.2), make four copies of this highlighted group
with an offset of 0.033 m in the X direction (Number of copies = 4, Translate with X offset =
0.033 m).
• Group all the pins by highlighting them in the Model manager window, right-click and select
Copy and finally make one copy as follows: Number of copies = 1, Translate with Y offset =
-0.03, Mirror with Plane: XZ and About: Low end.
The final model should appear as shown in Figure 6.4: Model with Heat Pipe and Heat Sink (p. 158).
Figure 6.4: Model with Heat Pipe and Heat Sink
6.6. Step 3: Create Nested Non-conformal Mesh Using Assemblies

In this exercise, our goal is to reduce the overall cell count to a reasonable level while retaining a good
cell resolution within the model, especially where the velocity and temperature gradients are higher.
1. Create three individual assemblies (one for the heat sink and the base, the second one for the vent,
and the last one for the fan).
a. Highlight all the pins and the base in the model manager window.
Step 3: Create Nested Non-conformal Mesh Using Assemblies
b. Right-click and select Create then Assembly.
c. Rename the assembly as Heatsink-asy.
d. Double-click the assembly to open the Edit panel.
e. Under the Meshing tab, toggle the Mesh separately button.
f. Set the slack to the following values:
Table 6.4: Slack Values for Heatsink-asy
Min X 0.005 m Max X 0.005 m

Min Y 0.005 m Max Y 0.005 m
Min Z 0.015 m Max Z 0.005 m
Note:
For the Heatsink-asy, you have set a bounding box that is 0.005 m bigger than the
assembly at five sides except Min Z where the slack is defined higher (0.015 m) to
capture the wake region of the flow. Also keep in mind that on the face Min Z is
where the wake occurs because the fan is of type Exhaust rather than of type Intake.
g. Click Update and Done.
h. Following the same procedure above, create two more assemblies; one for vent.1 (name it Vent-
asy) and one for the fan (name it Fan-asy).
i. Use the following tables to assign slack values for Vent-asy and Fan-asy assemblies, respectively.
Table 6.5: Slack Values for Vent-asy
Min X 0.01 m Max X 0.01 m

Min Y 0.01 m Max Y 0.01 m
Min Z 0.01 m Max Z 0m
Table 6.6: Slack Values for Fan-asy

Min Z 0m Max Z 0.01 m
2. Put the previously created assemblies into an outer assembly covering all.
a. Highlight all the three assemblies above and right-click your selection.
b. Select Create assembly.
c. Rename this main assembly HS-vent-fan-asy.
d. Assign the following slack values to the assembly.
Table 6.7: Slack Values for HS-vent-fan-asy

Min Z 0m Max Z 0m
1. Go to Model Generate Mesh or use the toolbar shortcut ( ) to open the Mesh control panel.
2. In the Mesh control panel, specify a global maximum element size of 0.025 m in all three directions
(Max X size = Max Y size = Max Z size = 0.025).
3. Verify that the Coarse option is selected next to Mesh parameters and change the Max size ratio
from 10 to 5.
4. Make sure that Mesh assemblies separately button is toggled.
5. Under the Options tab, set the Init element height to 0.003.
Figure 6.5: Mesh control Panel
6. Click Generate. Visualize the mesh by making plane cuts and surface displays under the Display
tab, especially between the heat sink pins and on the surface of the fan and grille objects. The
meshing panel should look like the one in Figure 6.5: Mesh control Panel (p. 161) when finished.
Note:
wizard to define your problem setup by double-clicking Problem setup in the model
manager window. See 2.7. Step 4: Physical and Numerical Settings (p. 28) of the Finned Heat
Sink tutorial for more instruction regarding the Problem setup wizard. You must still use
the same settings described in this tutorial for the Problem setup wizard.
1. Go to Problem setup Basic parameters. In the General setup tab, change the Flow regime
to be Turbulent and keep the default selection of Zero equation.
2. Go to the Transient setup tab and set the initial condition for the velocity in the Z direction to be
-0.1 m/s to achieve faster convergence. If there is an initial guess at the start of the solution there
is less of a chance of excessively large initial velocities in the first iteration.
Figure 6.6: Turbulent Flow and Initial Z Velocity (p. 162) shows these two steps. Click Accept for these
changes to take effect.
Figure 6.6: Turbulent Flow and Initial Z Velocity
3. Under Solution settings Basic settings, set the Number of iterations to 200 (Figure 6.7: Ba-
sic settings Panel (p. 163)).
Figure 6.7: Basic settings Panel
4. Click Accept.

to save the model (including the mesh) yourself as well.
File Save project

1. Add in two monitor points, one to monitor the velocity at the center of vent.1 and one to monitor
the temperature at the center of block.1.
a. Select vent.1 and block.1 from the list and then drag them to the Points branch of the tree.
(Alternatively, one can create monitor points by simply selecting these objects in the Model
manager window, clicking on the right mouse button and selecting Create and then Monitor
point.)
b. Because Ansys Icepak will by default monitor the temperature at the centroid or center of these
objects, double-click vent.1 under the monitor Points branch.
c. Select velocity as the variable to monitor and deselect temperature.
d. Accept the change.
2. Go to Solve Run solution or click the shortcut button ( ). Start the solver by clicking Start
solution.

To post-process the results for this exercise, create the following Object face and Plane cut objects:
Table 6.8: Object face and Plane cut Specifications
Ob- Specifications Description

ject
face.1 1. In the Object field, select all blocks Object face view of temperature contours on all the
blocks.
(Choose using the Ctrl and/or Shift
keys and left mouse button) Observations: The view shows the flow of heat
2. Select Show contours from the heated block (block.1) to the air-cooled
heat sink.
3. Click Parameters
4. Contours of: Temperature
5. Contour / Shading options: Solid fill
/ Smooth
6. Color levels: Calculated (Global limits)
cut.1 1. Go to the Plane location box Plane cut (X-Z) view of the velocity vector field.
2. Set position: Y plane through center
Observations: The view shows air flowing from
3. Click and drag the slider to around the vent to the fan as the air passes through the
0.800 array of fins.
4. Select Show vectors
5. Click Parameters
6. Color by: Velocity magnitude
The post-processing objects face.1 and cut.1 should look similar to Figure 6.8: Temperature Contours
on All Blocks (face.1) (p. 165) and Figure 6.9: Velocity Vector Field Around Fan and Heat Sink (cut.1) (p. 166).
Figure 6.8: Temperature Contours on All Blocks (face.1)
Figure 6.9: Velocity Vector Field Around Fan and Heat Sink (cut.1)

In this problem, you have modeled a simplified heat pipe using cylindrical solid blocks of orthotropic
conductivity. The exercise has also demonstrated the application of copy and mirror features as well as
the use of nested non-conformal meshing using assemblies in Ansys Icepak.
1. Best Practices
a. Reduce mesh counts and consequently decrease run times in regions requiring less resolution
b. Increase slack values for faces with a wake region if using a separately meshed assembly. Do
this to model the wake more accurately.
Step 9: Summary
2. Tips and Tricks
b. Choose appropriate solution initializations to achieve faster convergence.
Chapter 7: Non-Conformal Mesh
7.1. Introduction
This tutorial examines the effects of using a non-conformal mesh rather than a conformal mesh in a
simple pin-fin heat-sink problem.
• Generate a non-conformal mesh and related parameters such as slack values, maximum element
sizes, and so on.
• Understand the effects of a non-conformal mesh on total mesh count and results.
• Generate and compare summary reports.
• Apply non-conformal rules and restrictions.
Note:
7.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Ansys Icepak and that you have
explored the Sample Session in the Icepak User’s Guide and the tutorial Finned Heat Sink (p. 5). For
this reason, some steps in the setup and solution procedure will not be shown explicitly.

The model consists of a pin-fin heat sink composed of aluminum, which is in contact with a source
dissipating 10 W, as shown in Figure 7.1: Problem Specification (p. 170). The source-heatsink assembly
sits in the middle of a wind tunnel with a wind speed of 1.0 m/s. The ambient temperature is 20°C. The
flow regime is turbulent.
The objective of this exercise is to become familiar with the non-conformal meshing methodology and
its application. You will examine and compare the solution results of a conformal and a non-conformal
mesh.
In Ansys Icepak, you can mesh assemblies of objects separately. First, you define a region around an
assembly, then Ansys Icepak meshes this region independently of meshes external to your defined region.
Non-Conformal Mesh
This allows a fine mesh to be confined in a particular region of interest and helps to reduce overall
mesh count without sacrificing the accuracy of the results.

Open a new project and name it non-conformal.

• Cabinet ( )
Enter the following start and end locations for the cabinet.
xS 0.3 m xE 0.7 m
yS 0.5 m yE 0.7 m
zS 0.0 m zE 1.0 m
– Define an opening on the Cabinet boundary:
1. Open the Cabinet object panel.
2. In the Properties tab, change Wall type of Min z to Opening.
3. Click Edit to open the Openings panel.
4. In the Properties tab of the Openings panel, enter 1 m/s for the Z velocity and keep Temper-
ature as ambient (which is 20°C). Refer to Figure 7.2: Openings Panel for Wall Min z (p. 171).
Figure 7.2: Openings Panel for Wall Min z
Tip:
You can edit the ambient temperature setting, among other default settings, in the
Basic parameters panel.
– Define a grille on the Cabinet boundary:
Non-Conformal Mesh
1. Under the Properties tab of the Cabinet panel, change the wall type of Max z to Grille.
2. Click Edit to open the Grille panel.
3. In the Properties tab of the Grille panel, change the Free area ratio to 0.8 and leave the
other default property specifications.
Figure 7.3: Grille Properties Specifications
• Source ( )
Create a source using the following dimensions:
Object Specification
Name: source.1 xS = 0.48 m xE = 0.52 m Total power: 30 W
Geometry: Rectangular yS = 0.52 m yE = —
Plane: X-Z zS = 0.48 m zE = 0.52 m
Step 3: Generate a Conformal Mesh
• Heat sink ( )
Now, create a heat sink with the following geometrical and physical properties (Figure 7.4: Heat sinks
Panel (Specifications for Geometry and Properties) (p. 173)):
Figure 7.4: Heat sinks Panel (Specifications for Geometry and Properties)
7.6. Step 3: Generate a Conformal Mesh

Generate a conformal mesh for the model.
1. Open the Mesh control panel using Model Generate mesh or the Generate Mesh button ( ).
a. In the Mesh control panel, set the Max element size for X to 0.02 m, for Y to 0.01 m, and
for Z to 0.05 m.
b. Under the Global tab, select Normal next to Mesh parameters.
c. Under the Misc tab, select Allow minimum gap changes.
d. Click Generate.
Note:
The minimum gap for X, Y, Z may adjust to 10% of the minimum dimension in respect-
ive directions. Make a note of the number of elements, shown in the Mesh control
panel, as well as the face alignment range, displayed in the Message window.
2. Examine the mesh.
Non-Conformal Mesh
c. In the Set position drop-down list, select Y plane through center.
Note:
The mesh display plane is an X-Z plane cut through the center of the cabinet as shown
in Figure 7.5: Conformal Mesh, Central Y Plane (p. 174). Note the clustered mesh lines ex-
tending from the heat sink all the way across the domain in both the X and Z directions.
The total number of cells is about 144000.
Figure 7.5: Conformal Mesh, Central Y Plane
3. Disable the mesh display.
a. Deselect the Display mesh option.
b. Click Close to close the Mesh control panel.
Step 5: Save the Model

Before starting the solver, first review estimates of the Reynolds and Peclet numbers to check that Ansys
Icepak is modeling the proper flow regime.
Click Reset in the Basic settings panel. Check the values printed to the Message window. The Reynolds
and Peclet numbers are approximately 12600 and 8900, respectively, so the flow is turbulent.
Note:
Instead of accessing the Basic parameters panel as described below, you can instead
use the Problem setup wizard for guided problem setup by double-clicking Problem
setup in the model manager window. See 2.7. Step 4: Physical and Numerical Settings (p. 28)
1. To set up turbulent flow, go to Problem setup Basic parameters and choose the Zero
equation turbulence model under the General setup tab.
2. Forced convection is the predominant form of convection in this exercise. Natural convection is
negligible, so do not enable gravity. Also ignore radiation heat transfer as it is also negligible in
comparison to forced convection. This exercise is a steady-state analysis. Click Accept to accept the
new solver settings.
3. Go to Solution settings Basic settings and set the Number of iterations to 300.
4. Go to Advanced settings and specify Under-relaxation factors for Pressure, Momentum, and
Temperature as 0.7, 0.3, and 1.0 respectively.
5. Define a monitor point by dragging the source object (source.1) into the Points folder. This
creates a monitor point for the temperature of the object, which can be used to judge convergence
alongside the residuals.
Tip:
Speed up the convergence by initializing the solver with a Z velocity of 1.0 m/s in the
Transient setup tab of the Basic parameters panel.

to save the model before the solution. The model can be saved using File Save project.
Non-Conformal Mesh

Start the calculation by clicking Solve Run solution. Specify "conformal" as the ID. Click Start
solution to start the solver.

In this step, examine the maximum temperature using Ansys Icepak’s summary reporting tool.
Report Summary report
1. Define a report that will display temperature data for the source and the heat sink.
a. In the Define summary report panel, click New.
b. In the Objects drop-down list, select heatsink.1 and click Accept.
c. In the Value drop-down list, select Temperature.
d. Repeat steps (a) through (c) for source.1.
e. Click Write to generate a summary report.
Ansys Icepak opens the Report summary data panel, where minimum, maximum, and mean tem-
peratures for the heat sink and source are displayed. Note that the maximum temperature is about
37° C.
Step 8: Add an Assembly to the Model
2. Click Done to close the Report summary data panel.
3. Click Close to close the Define summary report panel.
7.11. Step 8: Add an Assembly to the Model

You will now create an assembly out of the source and heat sink objects. The assembly will be meshed
separately from the rest of the model.
Note:
Because you are changing the current model, thereby invalidating the post-processing data
that has been loaded from the previous steps, you will need to generate a mesh (a non-
conformal mesh) and calculate the solution again which is shown in steps 9 through 11.
1. Create an assembly consisting of the source and the heat sink objects.
a. Click the Create assemblies button ( ) to create a new assembly. This creates an assembly
node in the Model manager window under the Model node.
b. Select the source.1 item under the Model node in the Model manager window, hold down the
Ctrl key, and then select the heatsink.1 item.
c. Hold down the left mouse button, drag both highlighted items into the assembly.1 node of the
tree, then release the left mouse button.
Note:
You can also create assemblies by highlighting source.1 and heatsink.1 in the Model
manager window, then right-clicking one of the highlights, going to Create, then finally
selecting Assembly.
2. Edit the assembly and define its bounding box.
a. Select the assembly.1 node in the Model manager window, and then click the Edit object
button ( ) to open the Assemblies panel.
b. Click the Meshing tab.
c. Select the Mesh separately option and enter the Slack parameters shown in Figure 7.6: Slack
Values and Mesh Controls in the Separately Mesh Assembly (p. 178).
Non-Conformal Mesh
Figure 7.6: Slack Values and Mesh Controls in the Separately Mesh Assembly
This creates a bounding box region that is 0.05 m larger than the assembly on four sides. Since
Min Y is already at the bottom of the cabinet, no slack value can be provided for it. A larger
slack value of 0.15 m has been provided in the Max Z direction to resolve the wake region. Un-
check the Use global mesh control settings button. Click Copy global to copy the global mesh
settings. Then, set the Max X element size as 0.01 and the Max Z element size as 0.025. This
helps to refine the mesh within the separately meshed assembly.
Step 9: Generate a Non-conformal Mesh
d. Click Done to set the properties of the assembly and close the panel.
The new model is shown in Figure 7.7: The Source and Heat Sink in a Separately Meshed As-
sembly (p. 179).
Figure 7.7: The Source and Heat Sink in a Separately Meshed Assembly
7.12. Step 9: Generate a Non-conformal Mesh

Ansys Icepak can now mesh assembly.1 separately. The non-conformal mesh will limit the clustering
to a region inside a bounding box slightly larger than the source-heatsink assembly.
1. Generate a non-conformal mesh for the model.
Model Generate mesh
a. In the Mesh control panel, keep the Max element size for X set to 0.02 m, for Y set to 0.01
m, and for Z set to 0.05 m.
b. Under the Global tab, make sure the Mesh assemblies separately option is checked.
Non-Conformal Mesh
c. Click Generate to create the mesh.
Note:
Make a note of the number of elements, shown in the Mesh control panel, as well
as the face alignment range, displayed in the Message window.
b. Turn on the Cut plane option.
d. Turn on the Display mesh option.
The mesh display plane is an - plane cut through the center of the cabinet as shown in Fig-
ure 7.8: Non-conformal Mesh (p. 180). Note the clustered mesh lines extending from the heat sink
all the way across the domain in both the and directions only within the bounds of the as-
sembly. The total number of cells is about 101000.
Figure 7.8: Non-conformal Mesh
3. Turn off the mesh display.
a. Deselect the Display mesh option.
b. Click Close to close the Mesh control panel.

idea to save the model yourself as well.
File Save project

1. Retain the same Number of iterations (300) in the Basic settings panel.
2. Start the Solution.
Solve Run solution
a. Specify non-conformal as the solution ID.
b. Click Start solution to start the solver.
Note:
The monitor point that you already created is automatically used for the new solution.
Your residuals plot may look similar to Figure 7.9: Residuals Plot for the Non-Conformal Mesh (p. 182).
Note that the number of iterations is less than that of the solution using the conformal mesh. The
exact number of iterations required for convergence may vary on different computers.
Non-Conformal Mesh
Figure 7.9: Residuals Plot for the Non-Conformal Mesh

In this step, you will examine the maximum and minimum temperatures of the source and heat sink in
the new version of the model.
Report Summary report
1. Define a report that displays temperature data for the assembly.
a. Retain the same temperature report of the source and the heat sink, as used in the version
without the assembly.
b. Click Write to generate a summary report.
Step 13: Summary
Note that the reported temperatures (Figure 7.10: Report summary data for the Non-Conformal
Mesh (p. 183)) are very close to that obtained in the solution with the conformal mesh.
Figure 7.10: Report summary data for the Non-Conformal Mesh
2. Click Done to close the Report summary data panel.
3. Click Close to close the Define summary report panel.

In this tutorial, you generated both a conformal and a non-conformal mesh for a simple source-heatsink
geometry and compared the two sets of results. You found an approximate 20 percent reduction in
the number of cells for the non-conformal mesh with a negligible change in the temperature data. In
the process, you learned how to use slack values to create an appropriate bounding box for your sep-
arately meshed assembly.
1. Best Practices
a. Reduce mesh counts and consequently decrease run times by creating separately meshed assem-
blies that require a different mesh density. Also select suitable slack values that improve the
convergence rate while avoiding mesh bleeding.
b. Increase slack values for faces with a wake region if using a separately meshed assembly. Do
this to capture the wake more accurately.
2. Tips and Tricks
dundant work. This is faster than creating every object individually.
b. Initialize the solution with reasonable values to achieve faster convergence.
Chapter 8: Mesh and Model Enhancement Exercise
8.1. Objective
The objective of this exercise is to lead you through the decision making process involved in improving
a model. The inferences from the exercise should help you make appropriate modeling choices during
your next thermal modeling project.
Note:
8.2. Prerequisites
You should be familiar with:
• Ansys Icepak modeling objects
• Basics of meshing
• Non-conformal meshing
8.3. Skills Covered

In this tutorial, you will learn the following skills and be able to apply these skills in your own Ansys
Icepak projects:
• Basic meshing techniques
• Checking for and avoiding intersections between objects and assemblies
• Use of object separation setting
• Eliminating mesh bleeding
• Nested non-conformal meshing
Mesh and Model Enhancement Exercise
8.4. Training Method Used

This tutorial uses a troubleshooting approach. You are provided with a model with potential for improve-
ment. You will be given 15 minutes to try your hand at improving the model (you are not expected to
complete all the improvements in this short time). This will help you familiarize yourself with the issues
associated with the model. Then, an approach for improving the model is delineated in the form of
step-by-step hints. Feel free to explore the software interface as you work through these steps.
8.5. Loading the Model

2. Download the meshing_tutorial_start.zip file here.
3. Unzip the meshing_tutorial_start.zip file you have downloaded to your working directory.
4. Unpack and load the model named meshing-tutorial-start.tzr.
5. Rename it to any other name of your choice.
8.6. A 15 Minute Exploration

Without making any changes, the model results in about 700,000 elements. It is possible to reduce this
mesh significantly without compromising accuracy. You are allowed to modify, delete, or add objects
as long as the physics being modeled stays unchanged. You may want to refer to the power and ma-
terial specifications to justify model changes. Non-conformal meshing is one of the techniques that will
help you accomplish this task.
Work with this model for as long as you prefer within the allocated 15 minutes then stop and proceed
to the next set of instructions.
Hint:
Start by generating the mesh without making any changes. View mesh cut planes at various
orientations and locations to identify causes that result in unnecessary mesh clusters in non-
critical regions. Then modify the model in order to tackle the issues you notice.
8.7. Step-by-Step Approach

• Save the model you have been working on to another name. (You may be revisiting this model to
compare notes with the suggested approach)
• Reload the model you had unpacked earlier ("meshing-tutorial-start").
• Save it to another name of your choice.
Step-by-Step Approach
• Generate the mesh without modifying the model. You will see a mesh count of about 700,000 elements.
Note:
Ensure the mesh type is Mesher-HD.
• Create mesh cut planes in different orientations to identify the root cause for such a high mesh count.
One such cut plane (Z plane through center set position) is shown in Figure 8.1: A Mesh Cut Plane
View of the Given Model When Meshed Without Modifications (p. 187).
• Figure 8.1: A Mesh Cut Plane View of the Given Model When Meshed Without Modifications (p. 187)
shows that the high mesh count is due to grid bleeding from the heat sink and the components
cooled by it.
Note:
You can use non-conformal assemblies to avoid mesh bleeding in Ansys Icepak.
Figure 8.1: A Mesh Cut Plane View of the Given Model When Meshed Without Modifications
8.8. Modification 1: Non-Conformal Mesh of the Heat Sink and Compon-

ents
1. Create an assembly containing the heat sink and the components cooled by it (green colored objects).
Name it HS-asy.
Tip:
• Inside the graphics window, hold the Shift key, then click and draw a box around the
group of objects you would like to assemble.
• If you have trouble selecting the heat sink objects, you can make the mesh and some
objects invisible.
• You can also select the objects in the Model manager window by selecting heatsink.1
and then holding down Shift and clicking all objects with HS_component in their
name.
2. Mesh the non-conformal assembly with nonzero slack values.
a. Select Mesh separately under the Meshing tab of the Assemblies panel for this assembly (HS-
asy) and specify appropriate slack values (we recommend 1 mm on all sides as in Figure 8.2: Slack
Values for HS-asy (p. 189)). Furthermore, it is usually best practice to have 2-3 cells within the
slack region. You can verify the number of cells within a slack region by examining the mesh in
that area.
b. Click Copy global and then enter Max element size values for X, Y, and Z, respectively, 0.015
m, 0.01 m, and 0.0075 m.
Modification 1: Non-Conformal Mesh of the Heat Sink and Components
Figure 8.2: Slack Values for HS-asy
Note:
Make sure to update the units for the slack settings to mm.
Tip:
Use the Case check macro to ensure that no problematic assembly intersections exist.
In the Macros menu, select Productivity Validation Automatic Case Check
Tool. Click Apply for each case and note that there are no errors. Click Close when
finished.
c. Generate the mesh again.
d. Observe the decrease in element count. The mesh count should be around 300,000 elements
compared to the previous 700,000 element count.
Figure 8.3: Comparison Between the Non-Conformal Mesh and the Conformal Mesh (p. 190) shows
the difference between the non-conformal mesh and the conformal mesh you have generated.
Notice that in the non-conformal mesh, mesh bleeding is minimal. In the conformal mesh, the mesh
bleeds throughout the cabinet, resulting in a much higher overall mesh count.
Figure 8.3: Comparison Between the Non-Conformal Mesh and the Conformal Mesh
8.9. Modification 2: Non-Conformal Mesh for the hi-flux-comps Cluster

1. View cut planes of the mesh to see if you have any more unnecessary mesh bleeding. Figure 8.4: Mesh
Bleeding After 1 Non-Conformal Region (p. 191) shows one such cut plane.
• This time the unwanted meshing bleeding originates from the clusters of components named hi-
flux-comp (red colored objects).
Modification 2: Non-Conformal Mesh for the hi-flux-comps Cluster
Figure 8.4: Mesh Bleeding After 1 Non-Conformal Region
2. Create a non-conformal mesh around the cluster of components named hi-flux-comp.
Even though you are only interested in isolating the hi-flux-comp objects, there are two cylindrical
objects very close to it. You have two choices.
• Avoid the cylinders by using zero slack value. This may be too small and create a small gap
between the interface and the cylinders, which is not recommended because it can lead to cells
with high aspect ratios.
• Include the cylinders to the assembly. This is the suggested approach.
3. Create a non-conformal assembly named hfc-asy that includes the objects with the names hi-
flux-comp, Tab, Die, or cylinder-comp. See the objects highlighted in Figure 8.5: Objects for Assembly
hfc-asy (p. 192). Note that the Tab and Die objects are physically contained within the hi-flux-comp
objects.
Figure 8.5: Objects for Assembly hfc-asy
Modification 2: Non-Conformal Mesh for the hi-flux-comps Cluster
4. Edit the hfc-asy assembly and specify the slack settings as shown in Figure 8.6: Slack Settings for
Assembly hfc-asy (p. 193):
Figure 8.6: Slack Settings for Assembly hfc-asy
Note:
Make sure to update the units for the slack setting to mm.
5. Generate the mesh again.
6. Compare to the previous mesh and notice you have eliminated mesh bleeding originating from the
hi-flux-comp cluster (Figure 8.7: Mesh Bleeding Reduction due to Modification 2 (p. 194)).
Figure 8.7: Mesh Bleeding Reduction due to Modification 2
7. Repeat cut plane viewing. Figure 8.8: Mesh Bleeding from the Boards (p. 195) shows a cut plane view
after creating the two separate mesh regions. You can still eliminate the mesh bleeding emanating
from the boards.
Modification 3: A Super Assembly
Figure 8.8: Mesh Bleeding from the Boards
8.10. Modification 3: A Super Assembly

Reduce the mesh bleeding you see in Figure 8.8: Mesh Bleeding from the Boards (p. 195) by first creating
a separately meshed assembly of everything inside the enclosure: all model objects excluding the cab-
inet and the cabinet openings. Remember to mesh the assembly separately and use a slack value of 1
mm on all faces. Generate a mesh as you have previously. Notice that the mesh no longer bleeds beyond
the enclosure. Consequently, the mesh count (170,000 elements) is significantly lower than it was pre-
viously (300,000 elements).
Figure 8.9: Cut Plane View of Recursive Embedded Mesh (p. 196) shows the resultant Y-center cut plane
of the mesh.
Figure 8.9: Cut Plane View of Recursive Embedded Mesh
This method of creating a super assembly containing sub-non-conformal assemblies is called "nested
non-conformal meshing" or "recursive embedded meshing".
8.11. Modification 4: Separation Tolerance and Minimum Gap Settings

• Revisiting the Separation Setting
By default, Ansys Icepak accepts all minimum gap changes. We shall revisit these changes now.
– In the Mesh control panel, set all the Minimum gap settings to 1e-4 m (Figure 8.10: Minimum
gap Settings (p. 197)).
Modification 4: Separation Tolerance and Minimum Gap Settings
Figure 8.10: Minimum gap Settings
– In the Misc tab, deselect Allow minimum gap changes.
– Generate the mesh.
– The pop-up message as shown in Figure 8.11: Separation Warning (p. 198) will appear.
Figure 8.11: Separation Warning
– This warning appears because the gap (think of it as a tolerance setting for the mesher) distance
is larger than 10% of the smallest feature in the model.
– When there are objects smaller than the mesher tolerance, those objects will not be meshed cor-
rectly.
– However, note that the minimum gap setting is a useful tool designed to avoid unnecessary
meshing in regions with inadvertent geometry misalignments (without modifying the geometry)
or regions that do not require physical modeling.
– Look for the name of the object featured in the warning and its dimension.
– The warning is about the die objects, which are 0.0004 m in width.
Note:
Due to possibly different meshing priorities, you may get a warning for the object
Airgap first as the object’s thickness is equal to the minimum gap settings. Select
Change value and mesh if that warning appears.
→ These objects are power generating components, which are thin conducting plates. The warning
is about the width of the packages.
→ The surface area of the dies is a critical parameter affecting the temperature prediction for the
component. This cannot be simplified. Selecting Continue, don’t change would essentially ignore
the small geometry of the dies during meshing.
→ Hence, click Change value and mesh to accept the suggested change in the minimum gap
setting.
Note:
It is also possible to use a separation distance larger than the recommended 10%
value. Values of up to 50% (of the smallest dimension) may be used in cases where
reducing the mesh count is critical.
Additional Exercise: Local Mesh Refinement and Comparisons Between the Non-
Conformal and Conformal Meshes
– You will now get a separation warning about the tabs. You cannot change the geometry of the
tabs, so accept the suggested change in separation settings again.
Note:
You may get a message in the text window such as "16 values were modified by less than
minimum separation values to eliminate small gaps". The mesher is modifying the geometry
itself to get rid of problematic small gaps due to misalignments. In this exercise, the
modifications are negligible and thus do not cause a problem.
8.12. Additional Exercise: Local Mesh Refinement and Comparisons

Between the Non-Conformal and Conformal Meshes
• Refine the mesh locally for regions with higher gradients and therefore with greater resolution re-
quirements.
Tip:
The size of the first cells from critical heat-dissipating surfaces should be less than 1 mm
for a first cut analysis.
– View the mesh cut plane on the wall of the enclosure object, the PCB, and the critical heat gener-
ating components to see if you are fulfilling the above requirement.
– Use the Object params control in the Local tab of the Mesh control panel to specify mesh refine-
ment near all the important surfaces mentioned above. The Object params panel allows localized,
per-object mesh control. For an example, enter 0.001 for the Element height of the enclosure object.
A similar approach can be taken for the pcb object.(Figure 8.12: Per-object Meshing Paramet-
ers (p. 200)).
Figure 8.12: Per-object Meshing Parameters
• Generate the mesh to verify your changes.
• Now compare the conformal and non-conformal meshes.
Deselect the Mesh assemblies separately option in the Mesh control panels and generate the mesh.
The difference between the mesh with this check button selected and deselected is the effect of non-
conformal meshing.
• Problem setup, solution, and post-processing are beyond the scope of this exercise and are therefore
not explored.
• Compare the suggested approach to meshing with the approach you were attempting during the
initial 15 minute period of this tutorial.
8.13. Conclusion
You have significantly reduced the mesh count of a model through successive modifications to the
mesh. Consequently, the computing time and cost of the solution is much lower. Using approximate
object choices and enhanced meshing strategies, you have improved both the model and the mesh.
The approach delineated in this exercise can help reduce significant run time without compromising
the physics being modeled. Use the techniques you have learned in this tutorial to improve your meshes
in other projects.
1. Best Practices
a. Maintain 2-3 cells within a slack region.
Conclusion
b. Identify problematic areas within your mesh by visually inspecting it.
c. Reduce the cell count by eliminating mesh bleeding and choosing appropriate minimum gap
values.
d. Eliminate mesh bleeding by creating separately meshed assemblies.
e. Use the Case check macro to avoid intersections between different objects and/or assemblies.
f. Choose suitable slack values to avoid mesh bleeding while adequately reducing mesh count.
g. Ensure that the size of the first cells from critical heat-dissipating surfaces is less than 1 mm for
a first cut analysis.
2. Tips and Tricks
a. Make objects temporarily invisible or inactive when the objects obstruct your view in the
graphics window.
b. Select appropriate minimum gap values to avoid unnecessary meshing in regions with inadvertent
geometry misalignments or in regions where physical modeling is unneeded.
Chapter 9: Loss Coefficient for a Hexa-Grille
9.1. Introduction
This tutorial demonstrates how to define trials, run parametric solutions, and post-process the results.
Often, there is a need to calculate the loss coefficient of grilles that have certain hole patterns. The
purpose of the problem is to determine the minor loss coefficient of a grille that has hexagonal holes.
• Define a parameter to optimize the design.
• Define trials.
• Define primary and compound functions that you want to report.
• Calculate parametric solutions.
• Report and plot parametric results.
Note:
9.2. Prerequisites
solved or read the tutorial Finned Heat Sink (p. 5). Some steps in the setup and solution procedure
will not be shown explicitly.

The model includes a cabinet that is 160 mm in length with inlet and outlet openings at the two ends
(with cross sectional area of 7.363 mm x 12.7 mm), and four symmetry walls at the other sides. The
model also includes a part of the hexa-grille placed at the center of the channel in the streamwise dir-
ection, as shown in Figure 9.1: Problem Specification (p. 204). The grille has one full hexagonal hole at
the center and four quarter hexagonal holes placed around it. This pattern was selected because it
forms a periodic region and is sufficient to calculate the loss coefficient. The solution obtained from
this run can be replicated to form the solution for the entire domain.
Loss Coefficient for a Hexa-Grille

2. Download the loss_coefficient.zip file here.
3. Unzip the loss_coefficient.zip file you have downloaded to your working directory.
4. Copy loss-coefficient.tzr to your working directory.
5. Start Ansys Icepak, as described in Starting Ansys Icepak.
6. When Ansys Icepak starts, the Welcome to Icepak panel opens automatically.
8. The File selection panel appears.
9. In the File selection panel, select the packed project file loss-coefficient.tzr and click
Open.
10. The Location for the unpacked project file selection dialog appears.
Unpack.

This tutorial uses an existing model. Ansys Icepak displays the model in the graphics window, as shown
in Figure 9.2: Loaded Model (p. 205).
Figure 9.2: Loaded Model
Save the problem to a new project file.
This enables you to expand on the problem without affecting the original file.
File Save project as
1. In the Project text box, enter the name loss-coefficient-new.
2. Click Save.
9.6. Step 3: Define Parameters and Trials

You will first define a summary report of data at the openings. Next, you will specify a parameter, the
Reynolds number, and trials to vary the Reynolds number. You will also define primary and compound
functions to be reported. Primary functions are reported directly from Ansys Icepak, such as the static
pressure or mean velocity at the inlet. Compound functions are composed of one or more primary
functions, such as the loss coefficient.
1. Define the report that displays average velocity and pressure data at the inlet and outlet openings.
Solve Define report
Note:
The loss coefficient K is obtained by dividing the total pressure differential through the
domain by the average dynamic pressure, .
a. In the Define summary report panel, click New.
b. In the Objects drop-down list, select cabinet_default_side_maxx and click Accept.
c. In the Value drop-down list, select UX.
d. Repeat steps (a) and (b), then select Pressure in the Value drop-down list.
Step 3: Define Parameters and Trials
e. Repeat steps (a) through (d) for cabinet_default_side_minx.
f. Click the Close button to accept the settings and close the panel.
2. Define a velocity parameter at the inlet opening in terms of the Reynolds number ( ).
Note:
The velocity at the inlet opening in terms of the Reynolds number ( ), which is custom-
arily used in loss-coefficient plots in lieu of velocity, is calculated as , where
the kinematic viscosity ν = 1.84e-5 kg/m.s, and the hydraulic diameter of the duct Dh =
9.322e-3 m.
a. Select the inlet opening, cabinet_default_side_minx, in the Model manager window, and then
click the Edit object button ( ) to open the Openings panel.
b. Click the Properties tab.
c. Select X Velocity and set the value to $Re*1.84e-5/9.322e-3.
d. Click Done to set the properties of the opening. This opens the Param value panel.
e. Set the Initial value of Re to 10, and click Done to close both the Param value and the
Openings panels.
3. Define six trials according to the different values of the Reynolds number.
Solve Define trials
a. In the Parameters and optimization panel, ensure you have selected Parametric trials and All
combinations in the Setup tab.
b. Click the Design variables tab, enter the following values for the Reynolds number in the box
next to the Discrete values field: 10 50 100 500 1000 1750.
Click Apply to accept the changes.
Note:
Parameters values can also be exported/imported by clicking the Export or Import

button in the Setup tab of the Parameters and optimization panel. Clicking Export
or Import opens a file selection dialog box and overrides any existing data.
c. Click the Trials tab to review the trials. Ensure the Trials across top option at the bottom of
the tab is not selected, and click Reset to select Values instead of Numbered in order to use
the base names as values.
d. Do not close the panel yet. Proceed to the next step.
4. Set the parametric trials and define primary and compound functions.
a. While you are still in the Parameters and optimization panel, click the Setup tab.
b. Verify that the Parametric trials and All combinations options are selected.
c. Click the Functions tab.
d. Define four primary functions (Pstat_in, Pstat_out, Uave_in, and Uave_out).
Note:
These functions represent static pressures and average velocities at the inlet and
outlet, respectively.
i. Under Primary functions, click the New button to open the Define primary function panel.
ii. In the Define primary function panel, enter Pstat_in for the Function name.
iii. Select Report summary from the Function type drop-down list and cabinet_de-
fault_side_minx Pressure from the Item drop-down list and retain the selection of Max.
iv. Click Accept to accept the changes and close the panel.
v. Repeat steps (i) through (iv) for the following three functions:
Function Function type Item Max/Mean

name
Pstat_out Report summary cabinet_de- Max
fault_side_maxx
Pressure
Uave_in Report summary cabinet_de- Mean
fault_side_minx UX
Uave_out Report summary cabinet_de- Mean
fault_side_maxx UX
Important:
All function names are case-sensitive.
5. Define five compound functions (Pdyn_in, Pdyn_out, Ptot_in, Ptot_out, and Kfact).
a. Under Compound functions, click the New button to open the Define compound function
panel.
b. In the Define compound function panel, enter Pdyn_in for the Function name.
c. Next to Definition enter 0.5*1.1614*$Uave_in*$Uave_in.
d. Click Accept to accept the changes and close the panel.
e. Repeat steps (a) through (d) for the following four functions:
Function name Definition

Pdyn_out 0.5*1.1614*$Uave_out*$Uave_out
Ptot_in $Pstat_in+$Pdyn_in
Ptot_out $Pstat_out+$Pdyn_out
Kfact ($Ptot_in-$Ptot_out)/$Pdyn_out
6. Click Done to close the Parameters and optimization panel.

For this model, you will generate the mesh in just one step. The resulting mesh will be sufficiently fine
near object faces to resolve the flow physics properly.
Model Generate Mesh
1. Generate the mesh for the model.
a. Keep all the defaults in the Mesh control panel.
b. Click Generate in the Mesh control panel to generate the mesh.
Note:
The mesh display plane is an X-Z cut plane through the center of the cabinet as shown
in Figure 9.3: Mesh on the X-Z Plane (p. 215).
Figure 9.3: Mesh on the X-Z Plane
e. Deselect the Cut plane check box. Select the Volume check box.
f. In the Surface/volume options group box, select Selected object.
g. In the Model manager window, click block.1. View the volume mesh of the hex structure (Fig-
ure 9.4: Volume Mesh of Object block.1 (p. 216)).
Figure 9.4: Volume Mesh of Object block.1
3. Deselect the Display mesh option to turn off the mesh display.
4. Click Close to close the Mesh control panel.
Note:
Instead of accessing the Basic parameters panel as described below, you can instead
use the Problem setup wizard for guided problem setup by double-clicking Problem
setup in the model manager window. See 2.7. Step 4: Physical and Numerical Settings (p. 28)
1. Confirm that Ansys Icepak solves for only the flow variables (velocity/pressure) and that the flow
regime is laminar.
Problem setup Basic parameters
a. Keep the default selection of Flow (velocity/pressure) under Variables solved.
b. Under Radiation, select Off.
c. Keep the default selection of Laminar for the Flow regime.
d. Click Accept to close the panel.
2. Increase the Number of iterations to 500.
a. Enter 500 in the Number of iterations field.
b. Click Accept in the Basic settings panel.
3. Confirm under-relaxation factors are correct.
Solution settings Advanced settings
a. Make sure the Precision for the solver is Double.
b. Click Accept in the Advanced solver setup panel.

idea to save the model (including the mesh) yourself as well. If you exit Ansys Icepak before you start
the calculation, you will be able to open the project you saved and continue your analysis in a future
Ansys Icepak session. (If you start the calculation in the current Ansys Icepak session, Ansys Icepak will
simply overwrite your project file when it saves the model.)
File Save project

Start the calculation.
1. Solve Run optimization
Note:
Alternatively, you can click the button in the Model and solve toolbar to display the
Parameters and optimization panel.
2. Make sure Allow fast trials (single .cas file) is not selected in the Setup tab.
3. Click Run in the Parameters and optimization panel.

As Ansys Icepak starts performing the trials, the Parametric trials panel opens, displaying all the function
values defined previously, as well as parameters and running times for each trial. You can also open
the Parametric trials panel by selecting Show optimization/param results from the Report menu.
Report Show optimization/param results
Plot the loss coefficient, Kfact, against the Reynolds number, Re.
1. In the Parametric trials panel, click the Plot button to open the Selection panel.
2. In the Selection panel, select Re as the axis variable, and click Okay.
Step 9: Summary
3. In another Selection panel, which automatically opens up, select Kfact as the y axis variable, and
click Accept.
This displays the plot Kfact vs Re, as shown in Figure 9.5: Kfact vs Re Plot (p. 221)
Figure 9.5: Kfact vs Re Plot

In this tutorial, you have used the parameterization feature to calculate the loss coefficient of a grille
as a function of a varying Reynolds number (Re). You also defined other functions, such as static pressures
and velocities at the inlet and outlet, for Ansys Icepak to report as functions of the varying Reynolds
number. The results show that the loss coefficient decreases with an increasing Reynolds number. More
explicitly, the loss coefficient decays into an asymptote as the Reynolds number increases.
• Best Practice
– Use the Problem setup wizard for guided problem setup. Edit the problem setup if needed using
the Basic parameters panel.
• Tips and Tricks
– Use the Parameters and optimization feature to perform a parametric analysis of your system.
– Create your own independent variable, such as a varying Reynolds number, in the Design variables
tab of the Parameters and optimization panel.
– Define your own customized quantities for Ansys Icepak to report in the Functions tab of the
Parameters and optimization panel.
Chapter 10: Inline and Staggered Heat Sinks
Comparison
10.1. Introduction
This tutorial demonstrates how to use the check-box (boolean) parameter control for design variables,
and how to assign primary functions, in order to determine whether an inline or a staggered pin fin
heat sink performs better in a single model. You will compare the resulting maximum temperatures on
the package. Non-conformal meshing will also be used to reduce the cell count, required memory, and
run time. In addition, you will generate particle traces during the post-processing of the results.
• Define a check-box parameter (design variable).
• Define different values for a design variable.
• Run and report parametric trials.
• Clip a plane cut to align it with the sides of a heat sink assembly.
• Display particle traces coming from the fan and the opening.
Note:
10.2. Prerequisites

The model includes the package assembly, containing a BGA package object (compact conduction
model), inline or staggered assemblies consisting of the respective heat sink objects, PCB object,
spreader plate, a fan at the exit, and an opening at the inlet of the wind tunnel. The model geometry
is shown in Figure 10.1: Problem Specification (p. 224).
Inline and Staggered Heat Sinks Comparison

2. Download the heat_sink.zip file here.
3. Unzip the heat_sink.zip file you have downloaded to your working directory.
4. Copy the file heat_sink2b.tzr to your working directory.
5. Start Ansys Icepak, as described in Section 1.5 of the User’s Guide.
Note:
When Ansys Icepak starts, the Welcome to Icepak panel will open automatically.
Note:
The File selection panel will appear.
7. In the File selection panel, select the packed project file heat_sink2b.tzr and click Open.
Note:
The Location for the unpacked project file selection dialog will appear.
Unpack.
Note:
This tutorial uses an existing model. Ansys Icepak will display the heat sink model in the
graphics window. To view all components, expand all the assemblies of the model in the
Model manager window.
Note:
You can rotate the cabinet around a central point using the left mouse button, or you can
translate it to any point on the screen using the middle mouse button. You can zoom into
and out from the cabinet using the right mouse button. To restore the cabinet to its default
orientation, select Home position from the Orient menu.
Save the problem to a new project file.
Note:
This will allow you to expand on the problem without affecting the original file.
• In the Project name text box, enter the name heat-sink-new.
• Click Save.
10.6. Step 3: Define Design Variables
Note:
For both heat sinks, you will define the HeatSink parameter, which will activate/deactivate
heat sinks parametrically.
1. Define the HeatSink parameter for the Inline heat sink.
a. Select the Inline assembly in the Model manager window, and then click the Edit object button
( ) to open the Assemblies panel.
Step 3: Define Design Variables
b. Right-click the Active check box to open the Active parameter panel.
c. Select ON if variable is equal to this object’s name.
d. Enter $HeatSink in the Variable field.
Caution:
Note that all function names are case sensitive.
e. Click Accept in the Active parameter panel to accept the changes and close the panel.
f. Click Update in the Assemblies panel to open the Param value panel.
g. In the Param value panel, enter Staggered for the Initial value of HeatSink, and click Done
to close the panel.
Note:
The word Active in the Assemblies panel became green. Also, note that the Inline
assembly in the Model manager window is moved to the Inactive node.
h. Click Done in the Assemblies panel to close the panel.
2. Define the HeatSink parameter for the Staggered heat sink. Repeat the above steps for the
Staggered assembly:
a. Select the Staggered assembly and open its Assemblies panel.
b. Right-click the Active check box.
c. Select ON if variable is equal to this object’s name.
d. Enter $HeatSink in the Variable field.
e. Click Accept.
f. Click Done to exit the Assemblies panel.
Note:
You do not have to specify the initial value of $HeatSink again.
10.7. Step 4: Define Parametric Runs and Assign Primary Functions

You will first define values for your design variable. Next, you will review parametric trials and define
primary functions to be calculated and reported.
Tip:
Alternatively, you can click the button.
Step 4: Define Parametric Runs and Assign Primary Functions
1. Define parameter values.
a. In the Parameters and optimization panel, click the Design variables tab.
b. Next to Discrete values, after "Staggered" type in "Inline". Make sure to separate the
two with a space.
c. Click Apply to accept the changes.
2. Review trials.
a. Click the Trials tab.
b. Make sure that the Order for Staggered is 1, and for Inline is 2.
c. Select tr_HeatSink_Staggered as the Restart ID for the tr_HeatSink_Inline trial as shown in

the image below. This allows the second trial to use the first trial’s solution data to converge its
own solution more quickly.
Note:
Double-click in the Restart ID field to open the Restart ID selection panel.
Note:
If necessary, click Reset and then Values in the Trails naming panel to clear the
restart IDs.
3. Define a primary function.
Step 4: Define Parametric Runs and Assign Primary Functions
a. Click the Functions tab.
b. Click the New button in the Primary functions group box.
c. In the Define primary function panel, enter Tmax next to Function name.
d. In the Value drop-down list, select Maximum temperature of objects.
e. In the Object drop-down list, select the 700_BGA_40X40_5peripheral_p1.50 object in the

Package assembly, and click Accept.
f. In the Define primary function panel, click Accept to save the changes and close the panel.
g. Click Done in the Parameters and optimization panel to close the panel.

For this model, you will not generate a mesh in advance. Meshing will be automatically performed for
each design trial during the parametric trials.
Model Generate Mesh
1. Set the Mesh type to Mesher-HD.
2. In the Global tab, ensure that the Mesh assemblies separately option is selected.
3. Keep all other defaults in the Mesh control panel. Your panel settings should resemble those in
Figure 10.2: Mesh control Panel Settings (p. 233).
Figure 10.2: Mesh control Panel Settings
4. Click Close in the Mesh control panel to close the panel.
Note:
1. Define basic parameters.
a. In the Radiation box, select Off.
b. In the Flow regime box, select Turbulent and the Zero equation turbulence model.
c. In the Natural convection box, ensure the Gravity vector check box is not selected.
d. Your Basic parameters settings should resemble those in Figure 10.3: Basic parameters Panel
Settings (p. 234). Click Accept when you are done.
Figure 10.3: Basic parameters Panel Settings
2. Define basic settings.
a. Set the Number of iterations to 300.
b. Set Energy to 1e-8.
c. Click Accept in the Basic settings panel to accept the settings and close the panel.
3. Define advanced settings.
Solution settings Advanced settings
a. Set Precision to Double.
b. Click Accept in the Advanced solver setup panel to accept the settings and close the panel.

File Save project
10.11. Step 8: Monitor Points

Observe that monitor points have already been defined as shown in Figure 10.4: Monitor Points (p. 235).
The monitor point for the 700_BGA_4 package object is set for temperature monitoring, and the Xmax
opening object is set for velocity monitoring. You can set up your own monitor points by dragging and
dropping an object into the Points node.
Figure 10.4: Monitor Points
In addition to the residual plot, the monitor plot will display temperature at the center of the BGA
package object during the solution process and provide another indication of convergence as the
temperature settles on a fixed value.

1. Open the Parameters and optimization panel.
Note:
You can click the button in the Model and solve toolbar.
2. Click the Setup tab, and make sure that options Parametric trials and All combinations are selected.
Deselect Allow fast trials (single .cas file).
3. Click Run in the Parameters and optimization panel, to start the calculations.
Note:
As Ansys Icepak starts calculating solutions for the model, the Solution residuals window,
displaying convergence history, and the Temperature Point monitors window will open.
Also, the Parametric trials panel will open displaying the function values, as well as
parameters and running times for both trials, as shown in Figure 10.5: The Parametric
trials Panel (p. 236). The Parametric trials can also be opened by selecting Show optim-
ization/param results from the Report menu.
Figure 10.5: The Parametric trials Panel

The results from tr_HeatSink_Inline will be examined in this section.
1. In the Orient menu, select Orient negative Z.
2. Display velocity vectors on a plane cut at the exit region of the heat sink.
Post Plane cut
Tip:
You can also open the Plane cut panel by clicking the button.
a. In the Name field, enter the name cut_velocity.
b. In the Set position drop-down list, select Vertical - screen select.
c. Select a point in the graphics window between the fan and the heat sink assembly.
d. Select the Show vectors option, and click Parameters to open the Plane cut vectors panel.
e. Set the Arrow style drop-down list to 3D arrow heads.
f. In the Plane cut vectors panel, in the Color levels group box, select This object from the Cal-
culated drop-down list.
g. Your Plane cut vectors panel should resemble that in Figure 10.6: Plane cut vectors Panel (p. 237).
Figure 10.6: Plane cut vectors Panel
h. Click Done in the Plane cut vectors panel to accept the changes and close the panel.
i. In the Orient menu, select Isometric view.
Note:
The graphics window is updated, as shown in Figure 10.7: Velocity Vectors at the Exit
Region of the Heat Sink (p. 238)
Figure 10.7: Velocity Vectors at the Exit Region of the Heat Sink
3. Move this plane cut through the model.
a. While holding down the Shift key, click and hold down the middle mouse button on an edge
of the plane cut.
b. Drag the plane cut through the model in the graphics display window as shown below:
4. Clip the plane cut to align it with the sides of the heat sink assembly.
a. In the Orient menu, first select Orient positive X.
b. Click Rotate about screen normal , and then Scale to fit.
c. In the Plane cut panel (that was already opened), select Enable clipping, then click Max Y in
the orange region under Clip to box.
d. Click the top edge of the assembly in the graphics window.
e. In the Plane cut panel, click Min Z in the orange region under Clip to box.
f. Click the left edge of the assembly in the graphics window.
g. In the Plane cut panel, click Max Z in the orange region under Clip to box.
h. Click the right edge of the assembly in the graphics window.
i. Click the Update button.
Note:
The graphics window will be updated, as shown in Figure 10.8: Clipped Plane
Cut (p. 240)
Figure 10.8: Clipped Plane Cut
5. Display particle traces in a forward direction.
a. In the Orient menu, select Isometric view.
b. In the Plane cut panel, deselect Show vectors and Enable clipping and select Show particle
traces.
c. Click Parameters next to Show particle traces to open the Plane cut particles panel.
d. Select Speed from the Color variable drop-down list.
e. In the Point distribution options group box, keep the default selection of Uniform, and enter
50.
f. In the Style group box, ensure the Trail check box is selected. For Width, enter 3.
g. In the Color levels group box, select This object from the Calculated drop-down list. Your
settings should match those in Figure 10.9: Plane cut particles Panel (p. 241).
Figure 10.9: Plane cut particles Panel
h. Click Done to update the graphics window.
Note:
The graphics window will display the particle traces in the forward direction, as shown
in Figure 10.10: Forward Particle Traces (p. 242)
Figure 10.10: Forward Particle Traces
6. Display particle traces at the opening (Xmax).
a. In the Orient menu, select Orient negative Z.
b. In the Plane cut panel, deselect Active and click New.
c. In the Name field, enter the name opening-velocity.
d. In the Set position drop-down list, select Vertical - screen select.
e. Select a point in the graphics window near the opening (Xmax).
f. Select the Show particle traces option, and click Parameters to open the Plane cut particles
panel.
g. Select Speed from the Variable drop-down list.
h. In the display options group box, keep the default selection of Uniform, and enter 70.
i. In the Style group box, keep the default selection of Trail. Type 3 for Width.
j. In the Color levels group box, select This object from the Calculated drop-down list.
k. Click Done in the Plane cut particles and Plane cut panels to close the panels and update the
graphics window.
l. In the Orient menu, select Isometric view.
Figure 10.11: Opening Particle Traces

In this tutorial, you have used the optimization tool to determine whether an inline or a staggered pin
fin heat sink performs more effectively in this particular model. The resulting maximum temperature
on the package was found to be higher in the case of the staggered heat sink.
1. Best Practice
a. Use the Problem setup wizard for guided problem setup. Edit the problem setup if needed
b. Create monitor points of relevant quantities (temperature, pressure, or velocity) to help judge
2. Tips and Tricks
a. Select a preceding trial's name as the Restart ID for another trial to speed up the convergence.
b. Drag a plane cut through the model by pressing Shift while clicking the middle mouse button
on the edge of the plane cut.
Chapter 11: Minimizing Thermal Resistance
11.1. Introduction
Heat sink optimization is crucial in a variety of industrial applications. Usually, the challenge is to min-
imize the thermal resistance (or to maximize the heat transfer) and the amount of material used for the
heat sink. The objective of this tutorial is to minimize the thermal resistance for the big heat sink, while
keeping the maximum temperature in the entire system below 70°C and ensuring that the total mass
of the heat sinks does not exceed 0.326 kg.
• Set up an optimization problem.
• Define design variables.
• Define primary, compound, and objective functions.
• Set up an optimization problem and publish variables to Workbench for use in Ansys DesignXplorer.
Note:
11.2. Prerequisites
This tutorial assumes that you have little experience with Ansys Workbench but familiar with the menu
structure in Icepak and that you have solved or read the tutorial Finned Heat Sink (p. 5).

The model is composed of an FR-4 board (FR-4.1) of 20.32 cm 30.48 cm and 1.59 mm thick with
several components placed on the board (Figure 11.1: Problem Specification (p. 246)). Two grilles are
placed at the upstream and downstream of the board with the free flow area ratios of 60% and 50%,
respectively. There are also two components (block.1.3 and block.1.3.1) dissipating 5 W each.
There is a CPU (block.1) dissipating 50W and a heat sink (heatsink_small) is placed on the top of it.
Between the heat sink and the CPU, there is a thermal interface material (TIM_1) with a thermal con-
ductivity of W/mK. These components and three small power caps (power_cap_1.1, power_cap_1.1.1
and power_cap_1.1.2), dissipating 1 W each, form a non-conformal assembly (hs_assembly_1).
Minimizing Thermal Resistance
On the other side of the board, there are printed circuit boards racks, dissipating 20 W each, and a
parallel plate heat sink (heatsink_big) is placed on the top of the chips. Similar to the case of the small
heat sink, there is a thermal interface material (TIM_2.1 and TIM_2.1.1) between the large heat sink
and the chips with the same thermal conductivity. These components together form a non-conformal
assembly (hs_assembly_2).

2. Download the optimization.zip file here.
3. Unzip the optimization.zip file you have downloaded to your working directory.
4. Copy optimization.tzr to your working directory.
The File selection panel appears.
7. In the File selection panel, select the packed project file optimization.tzr and click Open.
8. The Location for the unpacked project file selection dialog appears.
Unpack.

This tutorial uses an existing model. Ansys Icepak will display the model in the graphics window. To
view all components, expand all the assemblies of the model in the Model manager window.
Note:
You can rotate the cabinet around a central point using the left mouse button, or you can
translate it to any point on the screen using the middle mouse button. You can zoom into
and out from the cabinet using the right mouse button. To restore the cabinet to its default
orientation, select Home position from the Orient menu.
Save the problem to a new project file (this enables you to expand on the problem without affecting
the original file).
1. In the Project name text box, enter the name optimization-new.
2. Click Save.
11.6. Step 3: Define Design Variables

The large heat sink needs to be optimized in terms of the number of fins and fin thickness. Therefore,
you will define the following design variables for the large heat sink: fin count (in the range from 2 to
18) and fin thickness (in the range from 0.254 mm to 2.032 mm).
1. Define the finCount and finThick design variables for the heatsink_big and specify their initial
values.
a. Expand the hs_assembly_2 node in the Model manager window.
b. Select the heatsink_big in the Model manager window and click the Edit object button ( )
to open the Heat sinks panel.
c. Click the Properties tab.
d. Under the Fin setup tab, type $finCount next to Count, and press Enter to open the Param
value panel.
Important:
All function names are case-sensitive.
e. In the Param value panel, enter 15 for the Initial value of finCount, and click Done to close
the panel.
f. In the Heat sinks panel, under the Fin setup tab, type $finThick next to Thickness, and
press Enter to open the Param value panel.
g. In the Param value panel, enter 0.762 for the Initial value of finThick, and click Done to close
the panel.
h. Click Done in the Heat sinks panel to close the panel.
2. Specify the constraint values for the design variables.
Tip:
Alternatively, you can click the button.
a. Turn on the Optimization option in the Setup tab. Then click on the Design variables tab.
The design variables that you had defined will be listed in the panel, and their initial values will
be shown in the Base value text box.
b. Select finCount from the list, then enter 2 for the Min value constraint, 18 for the Max value
constraint.
c. Select Allow only multiples, keep the default value of 1, and click Apply.
d. Select finThick from the list, then enter 0.254 for the Min value constraint, 2.032 for the
Max value constraint, and click Apply.
e. Make sure Allow only multiples is only activated for finCount, not finThick.
f. Click Done to close the Parameters and optimization panel.
Step 7: Define Primary, Compound, and Objective Functions

For this model, you will not generate a mesh in advance. Meshing will be automatically performed for
each design trial during parametric trials.
Model Generate Mesh.
1. Make sure that the Mesh type is Mesher-HD and the Mesh assemblies separately option is turned
on.
2. Make sure the Allow minimum gap changes is enabled in the Misc tab.
3. Click Close in the Mesh control panel to close the panel.

1. Keep all the defaults in the Basic parameters panel.
2. Click Accept in the Basic parameters panel to accept the settings and close the panel.
Solution settings Basic Settings
1. Make sure Number of iterations is 125.
2. Make sure the convergence criteria for Flow is 0.001, and for Energy is 1e-7.
3. Click Accept to close the Basic settings panel.

11.10. Step 7: Define Primary, Compound, and Objective Functions
Note:
The objective of this tutorial is to minimize the thermal resistance of the heat sink while
keeping the maximum temperature for the entire system below 70°C and ensuring that the
total mass of the heat sinks does not exceed 0.326 kg. Therefore, you will define the following
primary functions: thermal resistance for the large heat sink (bighsrth), mass of the large
heat sink (bighsms), mass of the small heat sink (smlhsms), and global maximum temper-
ature of 70°C (mxtmp). You will also define a compound function, the total mass of the heat
sinks of 0.326 kg (totalmass). For the objective function, you will minimize the thermal
resistance of the large heat sink (bighsrth).
1. Go to Solve Run optimization to open the Parameters and optimization panel.
2. In the Functions tab, define four primary functions.
a. Define the thermal resistance function for the large heat sink (bighsrth).
i. Click the New button under Primary functions.
ii. In the Define primary function panel, enter bighsrth next to Function name.
iii. In the Function type drop-down list, keep the default selection of Global value.
iv. In the Value drop-down list, select Thermal resistance of heatsink.
v. In the Object drop-down list, select the heatsink_big object under hs_assembly_2, and
click Accept to save the changes and close the panel.
b. Define the mass function for the large heat sink (bighsms).
i. Repeat step (a) for the bighsms as the Function name, Global value as the Function type,
Mass of objects as the Value, and heatsink_big as the Object.
c. Define the mass function for the small heat sink (smlhsms).
i. Repeat step (a) for the smlhsms as the Function name, Global value as the Function type,
Mass of objects as the Value, and heatsink_small as the Object.
d. Define a constraint function as the global maximum temperature of 70°C (mxtmp).
i. Click the New button under Primary functions.
ii. In the Define primary function panel, enter mxtmp next to Function name.
iii. In the Function type drop-down list, keep the default selection of Global value.
iv. In the Value drop-down list, keep the default selection of Global maximum temperature.
v. Select Constraint and keep the default selection of Max value.
Step 7: Define Primary, Compound, and Objective Functions
vi. Enter 70 in the text entry field and click Accept to save the changes and close the panel.
3. Define a compound function.
a. Under Compound functions, click the New button to open the Define compound function
panel.
b. In the Define compound function panel, enter totalmass for the Function name.
c. Next to Definition enter $bighsms+$smlhsms.
d. Select Constraint and keep the default selection of Max value.
e. Enter 0.326 in the text entry field and click Accept to save the changes and close the panel.
4. Define an objective function.
a. In the Parameters and optimization panel, select bighsrth from the Objective function drop-
down list.
b. Keep the default selection of Minimize value.

1. Open the Parameters and optimization panel, if it is not already opened.
Note:
Alternatively, you can click the button in the Model and solve toolbar.
2. Set up the optimization process.
a. In the Parameters and optimization panel, click the Setup tab.
b. Verify that the Optimization option is turned on, and keep all the defaults for this option.
c. Deselect Allow fast trials (single .cas file).
Note:
Due to the geometry change based on the fin thickness and fin count, the fast trials
option is not possible in this problem.
d. Select Sequential solution of flow and energy equations.
3. Click Run in the Parameters and optimization panel to start the calculations.

As Ansys Icepak starts calculating solutions for the model, the Optimization run window opens and
Ansys Icepak displays the function values, design variables, and the running times for each optimization
iteration. In addition, the function values and design variables are plotted versus iteration number, as
shown in Figure 11.2: The Optimization run Panel (p. 256).
Figure 11.2: The Optimization run Panel
Note:
Each iteration takes three trials.
11.13. Step 10: Optimization in DesignXplorer

• Start Ansys Workbench.
Note:
When Ansys Workbench starts, the Toolbox and Project Schematic are displayed.
Step 10: Optimization in DesignXplorer
• Add an Icepak template by dragging the template from the Toolbar under the Component Systems
node into the Project Schematic. Perform a right mouse click on the Setup cell. Select Import Icepak
Project and Browse to import the optimization-new project and launch Icepak.
• The model appears in the graphics display window. Click the isometric toolbar icon ( ) to display
the isometric view of the model.
• Go to Solve Run optimization to open the Parameters and optimization panel. Click on Publish
to WB to display the Publish to WB panel and select the green check marks to select all input and
output variables. Output variables for Workbench are primary and compound functions in Icepak.
Click Accept to save your specifications and click Done to close the panel.
• In Workbench, the Parameter Set is displayed. Right-click on A1 and select Update. Double click the
Parameter Set bar to display an outline of all parameters and the table of design points.
• Under the Design Exploration node in the Toolbox, add a Response Surface Optimization template
by dragging the template into the Project Schematic.
Double-click on the Design of Experiments cell. In the Outline of Schematic, select finCount. In
the Properties of Outline, select Discrete for the Classification property. In the Table of Outline,
create levels for 17, 18, and 19 fins. To minimize the time spent on the Design of Experiments, only
three fin counts will be studied.
Figure 11.3: finCount Setup
In the Outline of Schematic, select finThick. In the Properties of Outline, set a Lower Bound of
0.5 and Upper Bound of 0.625 and then select Manufacturable Values under Allowed Variables.
In the Table of Outline, create a level of 0.5625. The fin thicknesses will use only common values
rather than a fully continuous range.
Figure 11.4: finThick Setup
Select Design of Experiments in the Outline of Schematic. To minimize the design space, in the
Properties of Outline, select Box-Behnken Design for Design of Experiments Type. Then click
Preview to see a preview of design points.
Perform a right-mouse click on the Design of Experiments cell and select Update to run an optim-
ization. The optimization data will provide information of the variable affected the most by the different
combinations.
Figure 11.5: Design of Experiments
On the Project tab, right-click on the Response Surface cell and select Update. Then double-click
on the Optimization cell to open it. Right-click on Objectives and Contraints to insert objectives.
Then enter the objectives and constraints as shown in the figure below. Click Update to run an op-
timization.
Figure 11.6: Optimization Constraints
To see the Candidate Points selected, click on Candidate Points in the Outline of Schematic. The
optimal fin count and thickness are determined.

In this tutorial, you used the optimization tool to minimize the thermal resistance for the big heat sink.
The results show that Ansys Icepak predicts the best (optimized) case has a fin count of 19 and a fin
thickness of 0.5 mm. In this case, the maximum temperature for the entire system is determined to be
69.244°C (with the constraint of 70°C) while the total mass is 0.31659 kg (with the constraint of 0.326
kg). The objective function (thermal resistance) is predicted as 0.24338°C/W.
If we compare the results from DesignXplorer to Ansys Icepak, you will find similar results. In addition
further parametric and direct optimization methods can be tried.

You can also try to optimize the fin count and the fin thickness of both heat sinks and the free flow
area ratios of the inlet and exit grilles. A sample case may be as follows:
• Design variables
– Fin count for the large heat sink: 2-20
– Fin thickness for the large heat sink: 0.254-2.032mm
– Fin count for the small heat sink: 2-12
– Fin thickness for the small heat sink: 0.254-2.032 mm
– Free flow area ratio of the inlet grille: 30-80%
– Free flow area ratio of the exit grille: 30-80%
• Primary functions
– Thermal resistance for the large heat sink (bighsrth)
– Mass of the large heat sink (bighsms)
– Mass of the small heat sink (smlhsms)
– Maximum temperature for the entire system: 70°C (mxtmp)
• Compound function
– Total mass of the heat sinks: 0.45 kg (totalmass)
• Objective function
– Minimize the large heat sink thermal resistance (bighsrth)
Chapter 12: Radiation Modeling
12.1. Introduction
This tutorial demonstrates how to model radiation in Ansys Icepak. In this tutorial, you will learn how
to include the effects of radiation in a free convection environment with surface-to-surface (S2S), discrete
ordinates (DO) and ray-tracing radiation models.
Note:
12.2. Prerequisites
This tutorial assumes that you have worked on Sample Session and the tutorials Finned Heat Sink (p. 5)
and RF Amplifier (p. 51) in this guide.

Radiation heat transfer becomes significant at high temperatures and is typically more important for
natural convection problems as compared to forced convection problems in electronics cooling applic-
ations. Ansys Icepak provides three different models to solve for radiation effects: surface-to-surface
(S2S), discrete-ordinates (DO) and ray-tracing. This tutorial involves a source with a heat sink placed on
a printed circuit board (PCB) and is being cooled with natural convection. We will first solve the model
without radiation, then use the surface to surface model followed by the discrete ordinates and the ray
tracing models and lastly compare the results of all these four cases.

Open a new project and name it hsink-rad.

1. Open the Cabinet panel by double-clicking the Cabinet object in the Model manager window. In
the Geometry tab, enable the Fix values option to ensure the values are appropriately converted
as we use different units. Change all the units from m to mm. Then, input the following dimensions
in the Geometry tab of the Cabinet panel (Figure 12.1: Dimensions of the Cabinet and the Boundary
Condition Specifications (p. 266)).
Radiation Modeling
Figure 12.1: Dimensions of the Cabinet and the Boundary Condition Specifications
2. In the Properties tab of the Cabinet panel, define all the sides of the cabinet as shown above. The
Min y and Max y sides are defined as openings while all the remaining sides are stationary walls.
3. Click Done to close the Cabinet panel.
4. The printed circuit board (PCB), heat sink base and the fins of the heat sink will be constructed using
the block object in Ansys Icepak.
5. Create the PCB.
a. First, create a block and rename it as PCB in the Info tab of the Blocks panel.
b. Specify the dimensions of the block in the Geometry tab as shown below in Figure 12.2: Dimen-
sions of the PCB (p. 267).
Figure 12.2: Dimensions of the PCB
c. Click Done to close the Blocks panel.
6. Create a new material and assign it to the PCB.
a. Right-click the Model node and select Create object and then Material. A new node called
Materials will appear.
b. Expand the Materials node until you reach material.1. Double-click material.1 to open the
Materials panel.
c. In the Properties tab of the Materials panel, choose Orthotropic from the Conductivity type
drop-down list.
Radiation Modeling
i. Enter 40, 40, and 0.4 W/m-K for the X, Y, and Z directions, respectively.
d. Click Done to close the Materials panel.
e. In the Model manager window, double-click the PCB object we created to open the Blocks
panel again.
f. In the Properties tab of the Blocks panel, select material.1 from the Solid material drop-down
list as shown in Figure 12.3: Specifying material.1 as PCB Solid Material (p. 268).
Figure 12.3: Specifying material.1 as PCB Solid Material
g. Click Done to close the Blocks panel.
7. Create the heat sink base.
a. Create a new block and rename it as hs-base in the Info tab of the Blocks panel.
b. Specify the dimensions of the block in the Geometry tab as shown below in Figure 12.4: Dimen-
sions of the hs-base (p. 269).
Figure 12.4: Dimensions of the hs-base
c. Click Done to close the Blocks panel.
8. Create the fins.
a. Create a new block and rename it as hs-fin1.1 in the Info tab of the Blocks panel.
b. Specify the dimensions of the block in the Geometry tab as shown below in Figure 12.5: Heat
Sink Fin Dimensions (p. 270).
Radiation Modeling
Figure 12.5: Heat Sink Fin Dimensions
c. Leave all the other properties as their default values. Click Done to close the Blocks panel.
d. Create the remaining fins by using the copy feature.
i. Right-click the hs-fin1.1 object in the Model manager window and select Copy. The Copy
block hs-fin.1.1 panel opens.
ii. Set Number of copies to 8.
iii. Check the Translate option and set the X, Y and Z offset to 15, 0, and 0 mm respectively.
iv. Click Apply to close the Copy block hs-fin.1.1 panel and create the new fins.
9. Create a 75 W, 2D source.
a. Create a source using the Create sources button in the model toolbar.
b. In the Sources panel, specify the geometry and properties of the source according to Fig-
ure 12.6: Source at the Bottom on the Heat Sink (p. 271).
Note:
Click Update for the panel to display a value of 0 m for zE.
Tip:
Alternatively, you can use the snapping tools from the geometry window to align the
source’s dimensions to those of the Min z side of the hs-base block object. The
snapping tools here are labeled by their respective faces, such as xS, xE, yS, yE, and
so on.
c. Click Done to close the Sources panel and complete the creation of the model.
Figure 12.6: Source at the Bottom on the Heat Sink
Radiation Modeling
The final model should appear as shown in Figure 12.7: Schematic of the Model (p. 272).
Figure 12.7: Schematic of the Model

In order to generate a fine mesh on the heat sink and the neighboring regions while retaining a
coarser mesh in the remaining part of the model, create a non-conformal assembly enclosing all the
objects created and specify separate meshing parameters for this assembly.
1. Select the source (source.1), the base of the heat sink (hs-base), and all the fins (hs-fin1.1.x) in the
Model manager window together, then right-click and select Create and then Assembly.
2. Double-click assembly.1 in the Model manager window to open the Assemblies panel.
a. In the Meshing tab, click the Mesh separately button, and specify the slack values as well as
the max element sizes in each of the coordinate directions for the assembly as depicted in Fig-
ure 12.8: Meshing Parameters for assembly.1 (p. 274).
b. This refines the mesh inside the assembly and also prevents mesh bleeding by confining the
fine mesh to within the assembly.
c. Click Copy global and then enter the following Max element size for X, Y, and Z, respectively:
4, 10, and 4. Note that the unit should be specified as mm.
Note:
The units depicted in Figure 12.8: Meshing Parameters for assembly.1 (p. 274) are in
mm and m.
Radiation Modeling
Figure 12.8: Meshing Parameters for assembly.1
d. Click Done to close the Assemblies panel.
3. Once the assembly creation is complete, open the Mesh control panel by pressing the Generate
button.
a. Change the Mesh units to mm.
Note:
Doing so affects the parameters in the Max element size box.
b. Input the Max element size specifications according to Figure 12.9: Global Mesh Control
Parameters (p. 275).
Figure 12.9: Global Mesh Control Parameters
Radiation Modeling
c. Keep all other parameters as their default values.
d. Make sure Allow minimum gap changes is checked under the Misc tab.
e. Press Generate to create the mesh.
f. You can view the mesh using the Cut plane and Surface options available in the Display
tab.
g. Once you have finished viewing the mesh, make sure you deselect Display mesh in the
Display tab, and click Close to close the Mesh control panel.

Once the model is meshed, we will solve it for different situations, that is, with radiation off followed
by including the effects of radiation using both the surface-to-surface model as well as the discrete-or-
dinates and ray-tracing methods available in Ansys Icepak 13 and later.
12.8. Step 5: Solving the Model Without Radiation
Note:
1. Go to Problem setup Basic parameters.
a. Under the General setup tab (Figure 12.10: Basic parameters Panel (p. 277)):
i. Ensure that you have selected both Flow (velocity/pressure) and Temperature in the
Variables solved box.
ii. Because this is a natural convection problem select the Gravity vector check box.
iii. Select Laminar under the Flow regime group box.
Note:
Most natural convection models in electronics cooling are laminar, but it is

always good practice to compute the Rayleigh number to verify the flow re-
gime. For convenience, use the Dimensionless Parameter Calculator located
under Macros > Productivity.
iv. Select Off in the Radiation box to disable radiation effects.
Step 5: Solving the Model Without Radiation
Figure 12.10: Basic parameters Panel
b. Under the Defaults tab
i. In the Ambient conditions group box, set the Temperature and the Radiation temp to 40
C.
Note:
Temperature is the temperature of the ambient fluid, and Radiation temp is the
temperature of the surrounding enclosure surfaces used for radiation calculations.
c. Under the Transient setup tab
Radiation Modeling
i. Enter a small velocity value for the Y velocity such as 0.01 m/s.
Note:
In free convection flow problems, you should set a small initial velocity opposite
to the gravity vector’s direction.
ii. Retain the defaults for all other settings in the Basic parameters panel.
d. Press Accept to close the Basic parameters panel.
2. Go to Solution settings Basic settings.
a. Change your settings to match the values in Figure 12.11: Basic settings Panel (p. 278).
b. Click Accept to close the Basic Settings panel.
3. Go to Solution settings Advanced settings.
a. In the Advanced solver setup panel ensure that the Under-relaxation parameters for Pressure
and Momentum are 0.7 and 0.3, respectively.
b. Select Double from the precision drop-down list at the bottom of the panel (Figure 12.12: Ad-
vanced solver setup Panel (p. 279)).
Step 5: Solving the Model Without Radiation
Figure 12.12: Advanced solver setup Panel
c. Keep all other default options in the Advanced solver setup panel.
d. Press Accept to close the Advanced solver setup panel.
Radiation Modeling

idea to save the model (including the mesh) yourself as well.
File Save project
12.10. Step 7: Calculate a Solution: No Radiation

1. Go to Solve Run solution to bring up the Solve panel.
a. Enter norad as the solution ID.
b. Click Start solution at the bottom of the panel.
c. Once the solution residuals have converged you can post process the results using plane cuts
and object faces. Note the maximum value of temperature for comparison with successive runs
wherein radiative heat transfer will be enabled in the model.
Note:
You can check the maximum temperatures of each object by going to Report
Solution overview Create or by using the object summary report (Report
Summary report).
Figure 12.13: Temperature Results for the Model With Radiation Disabled
12.11. Step 8: Surface to Surface (S2S) Radiation Model

a. In the Basic parameters panel, select On in the Radiation group box.
b. Make sure the Surface to surface radiation model is selected.
c. Click Accept to close the Basic parameters panel.
2. To model radiation effects go to Model Radiation form factors or use the radiation icon ( )
to open up the Form factors panel.
Step 8: Surface to Surface (S2S) Radiation Model
a. Under Participating objects, select all objects by clicking All and leave all other settings to their
default values.
b. Press Compute to calculate the view factors.
i. You can display the view factors calculated in the text window by clicking each participating
object listed under Display object values. Select the object PCB displays the various form
factors of PCB in the graphics window (Figure 12.14: Form Factors of the PCB (p. 281)).
Figure 12.14: Form Factors of the PCB
ii. After reviewing the view factors, select Don’t recompute in the Form factor options group
box.
iii. The settings for the view factor calculations setup are shown in Figure 12.15: Enabling Radiation
in Ansys Icepak Model (p. 282).
Radiation Modeling
c. Press Close to close the Form factors panel.
Figure 12.15: Enabling Radiation in Ansys Icepak Model
3. Go to Solve Run solution and start the solver with S2S as the solution ID.
4. Once the solution residuals have converged, make note of the maximum temperature (Fig-
ure 12.16: Temperature Results for the Surface to Surface Radiation Model (p. 282)).
Figure 12.16: Temperature Results for the Surface to Surface Radiation Model
12.12. Step 9: Discrete Ordinates (DO) Radiation Model

Next, we will run the discrete ordinates radiation model.
a. Enable the Discrete ordinates radiation model option in the Radiation group box.
b. Press Accept to close the Basic parameters panel.
2. Start the solution again with DO as the solution ID.
3. Once the solution residuals have converged, make note of the maximum temperature (Fig-
ure 12.17: Temperature Results for the Discrete Ordinates Radiation Model (p. 283)).
Figure 12.17: Temperature Results for the Discrete Ordinates Radiation Model
12.13. Step 10: Ray-Tracing Radiation Model

Next, we will run the ray tracing radiation model.
a. Enable the Ray tracing radiation model option in the Radiation group box.
b. Press Accept to close the Radiation panel.
2. Start the solution again with Ray as the solution ID.
3. Once the solution residuals have converged, make note of the maximum temperature.(Fig-
ure 12.18: Temperature Results for the Ray-Tracing Radiation Model (p. 283))
Figure 12.18: Temperature Results for the Ray-Tracing Radiation Model

Compare the maximum temperature between the runs where radiative heat transfer was enabled versus
the runs where it was not. You can clearly see that radiation is important in this model and there is a
significant difference in the maximum temperature in the field with and without radiation. Further,
there is reasonable agreement in the plane cut post processing objects obtained using the different
radiation models. Figure 12.19: Plane cuts on the Z = 20 mm plane for (a) radiation disabled (b) S2S ra-
Radiation Modeling
diation model (c) discrete ordinates radiation model and (d) ray-tracing radiation model (p. 285) compares
the temperature fields for all the four cases.
Note:
In order to have the plane cuts located exactly at Z = 20 mm, go to the Plane location group
box of the Plane cut panel. Type 0.02 for the field PZ to set the plane at Z = 0.02 m, or 20
mm.
Figure 12.19: Plane cuts on the Z = 20 mm plane for (a) radiation disabled (b) S2S radiation model
(c) discrete ordinates radiation model and (d) ray-tracing radiation model
Radiation Modeling
Step 12: Summary
Table 12.1: Maximum Source Temperature for Different Models
No radiation 82.45°C
Surface to surface 74.97°C
Discrete ordinates 76.23°C
Ray tracing 75.55°C
Because the first case assumes no heat is rejected through radiation, there is less heat transfer and
therefore a higher maximum temperature when neglecting radiation. The radiation models all produce
similar results.
Note:
The actual values may differ slightly on different machines, so your values may not look exactly
the same.
In general, the surface to surface model is the fastest of the three radiation models in Ansys Icepak.
Therefore, you should use it for a first cut analysis. However, you cannot use the surface to surface
model when CAD objects are present. Note that the discrete ordinates and ray tracing models are more
accurate and better suited for more complex geometries. With a large number of participating surfaces,
the surface to surface model and ray tracing model cost significantly more computationally than the
discrete ordinates model.

In this problem you have learned how to model radiation in Ansys Icepak. You first solved the model
without radiation and then used the surface-to-surface model followed by the discrete ordinates and
ray tracing methods and lastly compared the results of all four cases.
1. Best Practice
b. Select the Allow minimum gap changes option in the Misc tab of the Mesh control panel to
c. Set a small initial velocity in an opposite direction to the gravity vector's direction when solving
natural convection problems.
d. Use the surface to surface radiation model for a first cut analysis, but switch to the discrete or-
dinates or ray tracing radiation models for higher accuracy.
e. Use the discrete ordinates or ray tracing methods when using CAD objects or when you require
a higher fidelity solution than what the surface to surface model can provide.
2. Tips and Tricks
Radiation Modeling
a. Select the Don't recompute option in the Form factors panel to re-use form factors and save
computational time.
Chapter 13: Transient Simulation
13.1. Introduction
The purpose of this exercise is to demonstrate how to model and post-process transient problems.
• Define a transient problem
• Specify time-dependent parameters for objects
• Group and copy modeling objects
• Examine the results of a transient simulation, including animating results over time
Note:
13.2. Prerequisites
This tutorial assumes that you have worked on Sample Session and the first two Ansys Icepak tutorials
of this guide (Finned Heat Sink (p. 5) and RF Amplifier (p. 51)).

The model involves a heat sink cooled by natural convection and heated by four heat sources attached
to the bottom. The power dissipated by each of the four sources varies with time and peaks at 100 W.

1. Create a new project called transient.
2. From Problem setup Basic parameters, go to the Transient setup tab, select Transient
under the Time variation group box. Then enter the Start and End times as 0 and 20 seconds,
respectively.
Transient Simulation
3. Click Edit parameters and set the Time step increment to 1 s and the Solution save interval to
1. Click Accept in the Transient parameters panel and then the Basic parameters panel to save
the new time parameters.
Caution:
The maximum allowable time step varies for each problem. Choosing an excessively large
time step may result in an insufficient temporal resolution and consequently instability
and divergence of the solution. However, choosing an excessively small time step may
result in slow convergence without a significant increase in accuracy.
Figure 13.1: Setting up the Model as Transient

Construct the model according to the following specifications. The final model is shown in Fig-
ure 13.4: Schematic of the Model (p. 294).
• Cabinet ( )
xS 0.05 m xE 0.35 m
yS 0.1 m yE 0.55 m
zS 0.05 m zE 0.25 m
Open the Cabinet object panel, go to the Properties tab, under Wall type, change Min y and Max
y to Opening. Press Done and then Shift+I for an isometric view.
• Plate ( )
Object Properties
Name: plate.1 xS = 0.1 m xE = 0.3 m Thermal model:
Conducting thick
Geometry: Rectangular yS = 0.2 m yE = 0.4 m Thickness: 10 mm
Plane: X-Y zS = 0.12 m — Solid material: default
(Al-Extruded)
• Blocks ( )
Object xC yC zC Height Radius IRadius Properties

Name: block.1 0.15 0.25 0.13 0.06 0.02 m 0.0 m Block type: solid
m m m m
Geometry: Solid material: default
Cylinder (Al-Extruded)
Plane: X-Y Radius2 IRadius2
Nonuniform 0.012 m 0.0
radius
Make two copies of the tapered fin (block.1), offset by 0.05 m in the X direction (Number of copies
= 2 and Translate with X offset = 0.05 m). Select all three tapered fins, and make two copies of
this group with an offset of 0.05 m in the Y direction (Number of copies = 2, and Translate with
Y offset = 0.05 m). Remember to right-click the icon in the Model manager window to copy objects
or alternatively press Ctrl + c while the objects are selected. These tapered cones model a heat sink
with tapered cone fins.
• Sources ( )
Create source.1, the first of four sources you will create, according to the specifications in the following
table:
Name: source.1 xS = 0.12 xE = 0.18 Total power = 100
m m W
Geometry: yS = 0.22 yE = 0.28
Rectangular m m
Plane: X-Y zS = 0.12
m
The 4 sources have a peak power of 100 watts each and a period of 20 seconds. The variation of
power is according to the following exponential curve, , where and are constant and
is the time.
In the Properties tab of the Sources panel, select Transient, click Edit, and enter 0 for Start time
and 20 for End time. To specify the variation curve, click Exponential and set a = 0.025 and b =
100. Click Update and Done, in the Transient power panel and then in the Sources panel.
Figure 13.2: Defining Transient Power for the Sources
Now make one copy of source.1 with an offset of 0.1 m in the X direction. Select source.1 and
source.1.1, then make one copy of these two sources with an offset of 0.1 m in the Y-direction to
complete the construction of the sources.
To view the time-dependent power specified for the sources, go to Problem setup Basic
parameters. Select the Transient setup tab and click View (next to Edit parameters) near the top
of this panel. This displays the time variation of the power specified using sources.
Figure 13.3: Viewing the Variation of Power on the Sources with Time
Tip:
A time dependent power profile such as a piecewise linear curve can also be imported/ex-
ported by clicking Save All and Load All in the Transients panel. Clicking Load All will
open the Load all curves file selection dialog box and override any existing data. Select
the CSV file containing the curve data and click Open.
The final model should appear as that shown in Figure 13.4: Schematic of the Model (p. 294).
Figure 13.4: Schematic of the Model

To generate a mesh for this model, go to Model Generate mesh and specify a global maximum
element size of 0.02 m in the X, Y and Z directions in the Max element size group box. Across from
Mesh parameters, select Normal and keep the default global mesh settings parameters. Then go to
the Options tab and select Init element height and enter 0.005. Then click Generate to create the
mesh. Once the mesh is generated, display and examine the mesh from the Display tab. Remember to
deselect the Display mesh option when you are done examining the mesh.
Note:
The Init element height is the first element’s height measured from the surface of the
solid into the fluid. This can be used in a relatively simple model as this one to increase
the boundary layer resolution. It is not recommended to be used for complex models
as this can create very large mesh counts.
Note:
Go to Problem setup Basic parameters. In the General setup tab, ensure Laminar is set for
Flow regime, and select the default Gravity vector (X = 0, Y = -9.80665 m/s2, Z = 0). In the Transient
setup tab, give a small initial (global) velocity of 0.001 m/s in the Y direction to increase the conver-
gence rate. Click Accept to accept the changes made and to exit this window.
Go to Solution settings Basic settings and click Reset to examine the estimated Rayleigh
number. A good starting point for iterations per timestep is 20. For the purposes of this tutorial, we'll
consider 20 iterations per timestep to be sufficient. Set Iterations / timestep to 20. Press Accept to
close the panel.
Note:
For real models, the number of iterations per timestep should allow the residuals to
drop three orders of magnitude at each timestep.
Go to Solution settings Advanced settings and set the Under-relaxation factors to 0.7 for
Pressure and 0.3 for Momentum. Also, ensure that Double is selected for Precision. Press Accept to
close the panel.
Create a monitor point to observe the temperature of source.1 with respect to time by dragging and
dropping source.1 into the Points folder in the Model manager window.

File Save project

Go to Solve Run solution. In the Results tab, click Write overview of results when finished and
click Start solution.
Figure 13.6: Convergence Plot (p. 297) shows the solution residuals for this exercise. Note that exact re-
siduals and number of iterations may vary on different computers. Each dip corresponds to the conver-
gence of an individual timestep, resulting in a total of 20 timesteps as you had initially specified.
Step 8: Generate a Summary Report
Figure 13.6: Convergence Plot
13.10. Step 8: Generate a Summary Report

1. Go to Solve Define report.
2. In the Define summary report panel, select Specified.
3. Select All times in the Report time group box.
4. Select New, hold down the Shift key and select all blocks in the Objects drop down list. Click Accept.
5. Click Write to display the Report summary data panel shown in Figure 13.7: Define summary report
Panel (p. 298).
• Note that the average temperature of the block objects starts at 20°C and increases to about 27°C
by the end of the 20 second duration.
Figure 13.7: Define summary report Panel

You can display the results of transient runs as still images or animations.
For still images, you can choose to display at a given time or a given time-step. To do so, after creating
post objects in the same manner as in a steady-state run, you can go to Post Transient settings or
click the transient settings icon ( ) to open the Post-processing time panel. To display at a given
time-step, you can select Time step and click Forward or Backward to step through the time steps.
To display at a given time, you can select Time value, input the time to begin the display and the time
Increment, and select Forward or Backward.
To view these images in this model, create the following post-processing objects:
Table 13.1: Object Face and Plane Cut Specifications
Object Specifications Description

face.1 Object: all blocks and Observation: The view shows the temperature distribution on
plate.1 the faces of all the blocks and the base plate. You can clearly
Show contours / Paramet- see the conduction of heat from the sources through the fins of
ers the heat sink.
Contours of: Temperature

Contours options: Solid fill
Shading options: Smooth
Color levels: Calculated /
Global limits
Post Transient set-
tings:
Time step: 1 or Time
value: 0
Forward or Backward
cut.1 Set position: Z plane Observation: The view shows air flowing from one opening to
through center the other. Also notice that the velocity distribution changes with
Show vectors / Paramet- time.
ers
Color by: Velocity
magnitude
Transient: Same as the
above
Figure 13.8: Transient Temperature Contour and Velocity Distribution Results at Various Time Values (p. 300)
shows the resulting static images at various time values. Note that at time = 0 the solver uses the
solution initialization you had previously specified as the resulting velocity distribution. As time pro-
gresses, heat dissipated by the sources spreads throughout the heat sink. Consequently, the overall
magnitude of the velocities increases due to the stronger natural convection at higher temperatures.
Figure 13.8: Transient Temperature Contour and Velocity Distribution Results at Various Time
Values
To animate the above post objects, go to Post Transient settings to open the Post-processing
time panel. Click Animate to open the Transient animation window. To animate the current display
on screen, click Animate in the Transient animation panel. The animation can be played once, from
the start time to end time, or in the Loop mode.
Tip:
In addition to animating the display in screen, you can also write the animation to a file in
MPEG, GIF, or other neutral formats to be played back later using a third-party software. To
do that, go to Post Transient settings, then click Animate to open the Transient anim-
ation panel. Select Write to file, then click Write to open the Save animation panel. Pick
a file format, give it a file name, and then click Save. This sequence saves the entire display
area with no scaling.
Alternatively, you can click the Options tab in the Save animation panel and modify the
Scale factor in the Save animation options panel. Also available in Save animation options
panel is Print region. Choose the default Full screen or Mouse selection. Choosing Mouse
selection allows one to draw a rubber band and select only a part of the screen. To do so,
choose Mouse selection, specify the file type and file name, then click Save in the Save
animation panel. With the cursor showing a square and the red prompt at the bottom of
the screen, draw a rectangular region with the left mouse to save it to the animation file.
You can examine how a variable changes over time at selected points using the History plot panel. To
open this panel, select History plot in the Post menu or click ( ) in the post-processing toolbar.
In the History plot panel, enter 20 seconds for End time, click the Add point button and select
source.1 for the point. Click the Create button to display the plot shown in Figure 13.9: History
plot (p. 303).
Step 10: Examine Transient Results in CFD-Post
Figure 13.9: History plot
13.12. Step 10: Examine Transient Results in CFD-Post

You can also postprocess results using tools in Ansys CFD-Post. Go to the Post menu in Icepak and select
Workflow data and click on CFD Post/Mechanical data. Enabling this option writes out a data file (fi-
lename.cfd.dat) that can be loaded into CFD-Post.
To launch CFD-Post for a Windows system, click Start > ANSYS 2021 R2>Fluid Dynamics>CFD-Post
2021 R2 or for a Linux system you can access CFD-Post using ~ansys_inc/v170/CFD-
Post/bin/cfdpost.
In Ansys CFD-Post, select Load Results... in the File menu to display the Load Results File dialog box.
Select the filename.cfd.cas file that corresponds to the transient solution.
Tip:
Refer to the Ansys Icepak text window for the location and file name of the transient solution
you have just saved.
Figure 13.10: CFD-Post
Once the results have been loaded into CFD-Post, there are several options to view and analyze a
transient solution.
1. Display time history similar to what is displayed in Icepak.
a. Go to Insert Text
b. Enter the text, Auto Annotation.
c. In the Definition tab of the Details view, enter Time into the Text String field.
d. Select the Embed Auto Annotation option.
e. In the Type drop-down list, select Timestep.
f. Click Apply.
Figure 13.11: Details of Auto Annotation
2. Create a contour.
a. Go to Insert Contour and create a new contour named TemperatureContours.
b. Update the settings for the Geometry tab of the Details view for TemperatureContours as
shown in Figure 13.12: Details of Temperature Contours (p. 306). Note that to select all of the
blocks as shown in the figure, you must click the ... button next to Locations, then you must
press Shift while selecting all of the block nodes in the panel that appears. Click Apply to create
the contours (Figure 13.13: TemperatureContours Display (p. 307)).
Figure 13.12: Details of Temperature Contours
Figure 13.13: TemperatureContours Display
3. Display temperature at different time steps.
a. Click the timestep selector icon ( ) to display the Timestep Selector panel. Double-click a
timestep to view the corresponding temperatures. Figure 13.14: Timestep Selector Panel (p. 308)
shows the selection of time 12.
Figure 13.14: Timestep Selector Panel
Additional options available in CFD-Post can be found in Postprocessing Using Ansys CFD-Post (p. 465).

In this tutorial, you set up and solved a transient model and used the animation technique to examine
the results over time. Results were also examined in CFD-Post.
1. Best Practices
b. Choose an appropriate time step to optimize the convergence rate while maintaining solution
stability.
c. Select an appropriate amount of iterations per time step for adequate temporal convergence.
Note that an individual time step may require fewer iterations to converge than you specify.
Step 10: Summary
2. Tips and Tricks
b. Set a small initial velocity in an opposite direction to the gravity vector's direction when solving
natural convection problems.
c. Post-process your transient simulation results at specific times in static images or through the
entire transient duration in animations.
d. Save your animations to a file in MPEG, GIF, or other neutral formats to be played back later using
a third-party software.
e. Load your results into Ansys CFD-Post for even more post-processing capabilities.
Chapter 14: Zoom-In Modeling in Ansys Workbench
14.1. Introduction
This tutorial demonstrates how to create and modify a zoom-in model (system sub-model) in Ansys
Icepak. You will begin in Ansys Workbench and drag an Icepak template into the Project Schematic
window. You will import an Icepak TZR file, modify the model, and solve it according to the instructions
in this tutorial. The project will also include post-processing results in Ansys CFD-Post.
• Create an Ansys Icepak analysis in Ansys Workbench
• Create a zoom-in model from a solved system-level model
• Run that model with more detail added
• Merge the detailed system-level model back into the system-level model
• Post-process results in CFD-Post
Note:
14.2. Prerequisites
This tutorial assumes that you have little experience with Ansys Icepak and Ansys Workbench, but that
you are generally familiar with the interface. If you are not, review Finned Heat Sink (p. 5) and the
Ansys Icepak - Ansys Workbench Integration Tutorial (p. 447) in this guide.

The objective of this exercise is to become familiar with Ansys Icepak’s zoom-in modeling capabilities.
You can solve detailed systems first with reasonable simplifications and then have more detailed sub-
system models run from boundary conditions created from the region in question. For example, you
can simplify multiple packages as one plate with the total power of all packages. You can then solve a
system level model, resulting in a sub-region with the velocities and temperatures from the system-
level model and have more detail on the board of interest. Essentially, you start with the most simplified
and all-encompassing system, then you progressively refine individual components of that system using
the results of the full, simplified system.
Zoom-In Modeling in Ansys Workbench
In this tutorial, you will run a simplified system-level model of a slotted chassis, learn how to create an
Ansys Icepak zoom-in model, run that model and then merge the detailed section back into the original
system.

2. Download the rack.zip file here.
3. Unzip the rack.zip file you have downloaded to your working directory.
4. Start Ansys Workbench.
Figure 14.2: Ansys Workbench
5. Copy rack.tzr to your working directory.
6. Drag and drop an Icepak template under Component Systems in the Toolbox window into the
Project Schematic window.
7. Right-click the Icepak Setup cell (A2) and select Import Icepak Project From .tzr.
8. Select Browse... and the File selection panel appears. Select the packed project file rack.tzr
and click Open.
9. The CAD model appears in the graphics window of Ansys Icepak. Click the isometric toolbar icon
( ) to display the isometric view of the model.
Note:
Look at the specifications of the different components. The model has 10 pairs of plates
(Figure 14.1: Problem Specification (p. 312)). If you examine any pair of plates, plate.1.x rep-
resents the PCB and plate.2.x represents the components on that PCB. In actuality, each
PCB would have many components mounted on it. We are simplifying the model by repres-
enting the components with a single plate. The thickness of these plates equals the average
height of the components. All the PCBs have the same configuration and the same compon-
ents. The total power of the components in each PCB is 30 W, so each of the plates (plate.2.x)
dissipates 30 W.
Save the problem to a new project file while you are in Ansys Workbench. This will allow you to expand
on the problem without affecting the original file.
File Save project
1. In the Project text box, enter the name rack-new.
2. Click Save.

For this model, you will generate the mesh in just one step. You will specify object-specific meshing
parameters to ensure that the resulting mesh is sufficiently fine near object faces to resolve the
boundary layers properly.
1. Go to Model Generate Mesh or use the toolbar shortcut ( ) to open the Mesh control panel.
2. In the Mesh control panel, make sure Mesher-HD is selected as the Mesh type.
3. Set the Max element size for X, Y, and Z to 0.03 m if not already set.
4. Select the Normal option next to Mesh parameters.
5. In the Local tab, select Edit next to Object params (Figure 14.3: Object Parameters in the Mesh
control Panel (p. 315)). Specify the individual localized mesh settings for the following objects using
the values in the table:
Object type Object name Parameter Requested Value

Opening All openings Y count 10
Plate All plates Low end height 0.003
High end height 0.003
Block block.3 Y count 4
Tip:
You can specify the parameters of multiple objects simultaneously by selecting all the
desired objects in the node tree of the Per-object meshing parameters panel then
making the required parameter specifications. Note that this can only be done to objects
of similar type and orientation.
Note:
You can also set mesh parameters by right-clicking object in the Model manager window
and selecting Edit mesh parameters.
Figure 14.3: Object Parameters in the Mesh control Panel
6. Press Done to close the Per-object meshing parameters panel.
7. In the Settings tab of the Mesh control panel, Generate the mesh and then display and visually
inspect the mesh from the Display tab. Deselect the Display mesh option when you are done.
8. Examine the mesh quality by going to the Quality tab of the Mesh control panel. Click Close when
you are done.

1. Go to Solution settings Basic settings and Solution settings Advanced settings.
Verify that the following values are set for each parameter:
Basic settings Specifica-

tion
Number of iterations 300
Energy convergence criterion 1e-7
Advanced settings (Under-relaxation group box)
Pressure 0.7
Momentum 0.3
2. Go to Problem setup Basic parameters and make sure the Flow regime is Turbulent
and the turbulence model is Zero equation under the General setup tab. Also select Off in the
Radiation group box. Click Accept to close the panel.
Note:
Instead of accessing the Basic parameters panel, you can instead use the Problem
setup wizard to define your problem setup by double-clicking Problem setup in the
model manager window. See 2.7. Step 4: Physical and Numerical Settings (p. 28) of the
Finned Heat Sink tutorial for more instruction regarding the Problem setup wizard. You
must still use the same settings described in this tutorial for the Problem setup wizard.
3. Now add two temperature point monitors for plate2.1 and plate2.2 into the Points folder to observe
the progress of the solution at the center of the objects. To do this, highlight both objects in the
Model manager window using the Ctrl key and the left mouse button, and then drag the objects
into the Points folder. The default monitored parameter is temperature.

calculation, you will be able to open the project you saved and continue your analysis in a future Ansys
overwrite your project file when it saves the model.)
File Save project

1. Go to Solve Run solution menu and select Sequential solution of flow and energy equations
in the General setup tab (Figure 14.4: The Solve Panel (p. 317)). Under Solver options, ensure that
Disable radiation is selected.
Figure 14.4: The Solve Panel
Tip:
When the gravity vector is not enabled in the solver, you have the opportunity to reduce
solve time if desired by selecting Sequential solution of flow and energy equations.
Since there are no buoyancy effects, there is no longer coupling of the Navier-Stokes and
energy equations. Thus, you can completely converge the flow equations and then use
that value in the energy equation instead of solving both on every iteration.
2. Click Start solution to run the solver.

1. After the solution has converged, create the following post processing objects with the settings
specified in the images:
• Object face: face.1
• Object face: face.2
Select all the fan objects for face.2.
Click Animate in the Object face particles panel to see the fluid streamlines animated according
to the steady-state velocity distribution.
• Plane cut: cut.1
• Plane cut: cut.2
The post-processing objects face.1 and cut.1 should look similar to Figure 14.5: Object Face: face.1
(plate2.2 Temperature) (p. 320) and Figure 14.6: Plane Cut: cut.1 (Z Plane Through Center Velo-
city) (p. 321).
Figure 14.5: Object Face: face.1 (plate2.2 Temperature)
Step 8: Create a Zoom-In Model
Figure 14.6: Plane Cut: cut.1 (Z Plane Through Center Velocity)
2. Save all the post-processing objects created. Go to Post Save post objects to file. Save it with
the default file name post_objects to be used in the future.
14.11. Step 8: Create a Zoom-In Model

With a solution obtained for the main model, we can now zoom-in around one pair of PCB-components
plates, namely plate.1.2 and plate.2.2.
1. Go to Post Create zoom-in model. The Zoom-in modeling panel appears. The boundaries for
the zoom-in also appear in the Ansys Icepak main window as a bold white box. By default this zoom-
in box is coincidental with the cabinet.
2. Resize this box by entering the values shown in Figure 14.7: The Zoom-in modeling Setup Panel (p. 322)
into the zoom-in window. Change Max Y to Outflow and both Min Z and Max Z to Wall. Note that
the zoom-in box now surrounds plate.1.2 and plate.2.2 and includes portions of some on the remain-
ing system-level model objects (Figure 14.8: Zoom-in Box (p. 324)). There needs to be one outflow
to compensate for slight differences in flow with a pressure differential. The wall objects are created
since the entire face on that side is created in a solid or on a solid surface.
Note:
The coordinates for each of the zoom-in boundaries can also be specified by clicking the
Select button to the right of the appropriate text entry box and clicking the left mouse
button on the desired point in the graphics display window. You may want to orient your
view depending upon the coordinate being selected to ensure a more accurate selection.
The boundaries of the zoom-in model will be displayed in the graphics window as you
update them.
Figure 14.7: The Zoom-in modeling Setup Panel
3. Click Accept to create the zoom-in model. Since many of the parts in the zoom-in model extend
out of the zoom-in box, a warning message window should appear listing a set of objects that lie
outside.
Step 8: Create a Zoom-In Model
4. In the Objects overlapping dialog box, click the Resize button to resize these parts to fit into the
zoom-in model. Ansys Icepak writes out a zoom-in model called IcepakProj.zoom_in. Ansys Ice-
pak reports on the operations to construct the model and creates the profiles in the Ansys Icepak mes-
sages window.
Figure 14.8: Zoom-in Box
Step 9: Edit the Zoom-in Model
14.12. Step 9: Edit the Zoom-in Model

1. Drag and drop a new Icepak template into the same Ansys Workbench Project schematic window,
then link a Results cell from the Toolbox window to this Icepak template (name it Zoom-in). The
Results cell should link to the Icepak Solution cell as shown in Figure 14.9: Project Schematic (p. 325).
Figure 14.9: Project Schematic
Note:
Click Update Project in Ansys Workbench to update the setup and solution data before
creating a new Icepak template. This will mesh and solve your Icepak model again.
2. Right-click the Icepak Setup cell (B2), select Import Icepak Project and Browse....
3. In the Select Folder file selection dialog, select the zoom-in model called IcepakProj.zoom_in. (It
will be in the same location as the folder for the system-level model.) In the system-level model we
used a single conducting thick plate to represent the components. We can now replace the plate.2.2
by the individual components.
4. Double-click plate.2.2 to open the Plates panel and make the following changes:
a. In the Info tab, type Chip for the Name field.
b. In the Geometry tab, change your settings to match those in Figure 14.10: Plates Panel for Object
Chip (Geometry Tab) (p. 326).
Figure 14.10: Plates Panel for Object Chip (Geometry Tab)
c. In the Properties tab, type 3.0 W in the Total power field.
d. Click Done to close the panel.
5. Create nine additional components in an array.
a. Right-click Chip and select Copy.
b. Create two copies of Chip with a Z offset of -0.065 m.
c. Select and highlight all three Chip plates in the Model manager window.
d. Make three copies of the three plates with an Y offset set to 0.07 m in the same way you
copied the single chip.
e. View the geometry in isometric view (Shift+I).
f. Delete two of the components (Chip.1.3 and Chip.4) and to form the pattern shown in Fig-
ure 14.11: Schematic of the Completed Zoom-in Model (p. 327).
Step 10: Mesh the Zoom-In Model
Figure 14.11: Schematic of the Completed Zoom-in Model
14.13. Step 10: Mesh the Zoom-In Model

1. Go to Model Generate mesh, and set the Mesh type to Mesher-HD and the Mesh parameters
to Coarse.
2. In the Local tab, deselect the Object params check box.
3. While in the Global tab, change your mesh settings to those of Figure 14.12: Zoom-in Mesh control
Panel (p. 328).
Figure 14.12: Zoom-in Mesh control Panel
4. Generate the mesh and then display and check the mesh quality from the Display tab. Make sure
to deselect the Display mesh option when you are done.
14.14. Step 11: Zoom-In Physical and Numerical Settings

1. Drag and drop the two chips (Chip.5 and Chip.2.3) into the Points folder in the Model manager
window to monitor their temperature.
2. Delete the monitor point plate.2.2 brought in from the system-level model since it no longer exists
as an object. Also delete any other monitor points beside Chip.5 and Chip.2.3.
Step 12: Examine the Zoom-in Results
3. Go to Solution settings Basic settings to change the maximum number of iterations to

300.
4. Solve the model by selecting Solve Run solution and by clicking Start solution under the
General setup tab.
14.15. Step 12: Examine the Zoom-in Results

After the solution has converged, create the following post-processing objects and compare the results
with the system-level models.

face.1 Object: all chips Object-face view of temperature on all chips
Show contours / Para- Observation: The temperatures are highest in the middle chips
meters toward the lower Z end of the chip array.
Contours of:
Temperature
Contours options: Solid
fill
Shading options:
Smooth
Calculated: This object
face.2 Object: Object-face showing the flow pattern
side_opening.miny
Show particle traces / Animate the particle traces.
Parameters
Observation(s): The flow is relatively uniform along the lower
Variable: Speed
Y end of the model and ultimately speeds up near the high Y
Particle options and low Z end of the model.
Start time: 0; End time:
1
Point distribution op-
tions: Uniform = 100
Style: Trail selected;
Marker: dot
Figure 14.13: Object Faces face.1 and face.2 (p. 330) shows the two object faces simultaneously.
Figure 14.13: Object Faces face.1 and face.2

If you were to model all the components in the system-level model, you would have ended up with a
cell count of about ten times the size of the zoom-in model. The simplifications at the system-level
enabled you to quickly solve the system-level model. The zoom-in model showed you the temperature
variation at the sub-system-level, which was essential to identifying the correct locations of the hot
spots.
1. Best Practices
a. Use zoom-in modeling when analyzing a complicated system to refine the individual modeling
of complex sub-systems.
b. Manage your project from Ansys Workbench when performing zoom-in modeling.
Step 15: Additional Exercise 2
c. Specify object-specific meshing parameters for local mesh refinement in regions with high
gradients.
2. Tips and Tricks
a. Specify the parameters of multiple objects simultaneously by selecting all the desired objects in
the node tree of the Per-object meshing parameters panel then making the required parameter
specifications. Note that you can only do this to objects of similar type and orientation.
b. Use the Problem setup wizard for guided problem setup. Edit the problem setup if needed
c. Select Sequential solution of flow and energy equations in the Solve panel when you are
not considering the effects of natural convection. This reduces the solution time required by
converging the flow equations before the energy equation rather than simultaneous computation
on each iteration.
14.17. Step 14: Additional Exercise 1

Set up this problem in a Workbench-based Icepak project. Then set up another Icepak component in
the same Workbench project schematic and replace the PCB plate with a detailed PCB object and post-
process the results in Ansys CFD-Post.
You can then perform a comparison study in Ansys CFD-Post by creating a third Icepak component.
This time, duplicate the first Icepak component and link this component to the available Results com-
ponent. Post-process the results in Ansys CFD-Post and compare them to the results containing the
PCB plate object.
14.18. Step 15: Additional Exercise 2

Perform this additional exercise to create a non-conformal mesh assembly surrounding the details of
the third PCB in the main model. Then, compare the results obtained using a non-conformal meshed
assembly to the results obtained using the main model with a conformal mesh and to the ones from
the zoom-in modeling approach with a conformal mesh.
1. Save the IcepakProj.zoom_in model with a new model name such as rack.zoom_in_merge.
Double-click the Icepak component module’s name (component B) and then enter
rack.zoom_in_merge for the module name.
2. Delete all the components within the model except all the plates which represents the PCB and the
chips and re-save the model. This version has all the unnecessary components for the system merge
removed.)
3. Rename Icepak component module A as rack-merge-NC as shown:
4. Open the main model rack.
5. Use File Merge Project to import rack.zoom_in_merge into this model with all the details of
the chips.
Note:
There will be two projects in the rack-new_files folder, IPK and IPK-1. Select IcepakProj
located at dp0/IPK-1/Icepak.
6. Deactivate the old components residing where the merged components are (plate.1.2 and plate.2.2).
7. Create a non-conformal assembly containing all the chips and the board. Use slack values between
3-5 mm in every direction for the assembly. These are good values to start without violating any
of the non-conformal meshing rules.
8. Finally, mesh and run the model with a different Solution ID and compare the results to the previ-
ously obtained ones. Verify that the results are very comparable.
Figure 14.14: Temperature Comparison: Zoom-in Model with Conformal Meshing vs. System with
Non-conformal Assembly (p. 333) shows a temperature comparison between the zoom-in model and
the system-level model with a non-conformal assembly. While the temperatures are slightly different,
the overall distribution (hot spots) stay the same.
Step 15: Additional Exercise 2
Figure 14.14: Temperature Comparison: Zoom-in Model with Conformal Meshing vs. System
with Non-conformal Assembly
Chapter 15: IDF Import
15.1. Introduction
This tutorial demonstrates the IDF import capability of Ansys Icepak.
• Import IDF files.
• Apply the various options offered in Ansys Icepak’s IDF import capability.
Note:
15.2. Prerequisites
solved or read the tutorial Finned Heat Sink (p. 5). If you have not, review Sample Session in the Icepak
User’s Guide.

Intermediate Data Format (IDF) is a data exchange specification between ECAD and MCAD for the design
and analysis of printed circuit boards. An IDF CAD model is generated by software such as Mentor
Graphics. Typical IDF models include a board file and a library file. The board file includes board layout
(board dimension and shape, location of the components), and the library file includes component in-
formation (size, power dissipation, junction to case and junction to board thermal resistance, etc.). Ansys
Icepak’s IDF import utility is designed to convert the IDF CAD data into an Ansys Icepak model automat-
ically. Ansys Icepak imports the geometry as well as parameters such as power and material property
based on the availability of such information.
This tutorial does not involve generating a mesh, calculating a solution or examining results. These
steps will not be shown in this tutorial.

1. Start Ansys Icepak, as described in Starting Ansys Icepak on a Linux System and Starting Ansys Icepak
on a Windows System of the User’s Guide.
IDF Import
3. Specify a name for your project.
a. In the Project name text box, enter the name idf-demo.
b. Click Create.

2. Download the idf_import.zip file here.
3. Unzip the idf_import.zip file you have downloaded to your working directory.
To build the model, you will first import the board layout. The board and the associated library files
have to be chosen at this step.
File Import IDF file New
Figure 15.1: IDF Import Menu
1. In the IDF import panel, click the Browse button next to the Board file (ascii) field and select the
file brd_board.emn. Board files have the extension "*.emn," "*.bdf," "*.idb," or "*.brd". Note that
the library file (brd_board.emp) is loaded automatically (Figure 15.2: IDF import Panel - Load
files (p. 337)).
Figure 15.2: IDF import Panel - Load files
2. Click Next and go on to the Layout options section (Figure 15.3: IDF import Panel - Layout op-
tions (p. 338)).
• Import type as Detail
IDF Import
• Board plane as XY - this is always detected automatically
• Board shape as Rectangular
• Board properties - Click Edit button to access the Board properties where you can enter details
such as number of trace layers, coverage, layer thickness, and so on. Layer properties refer to the
average properties of all internal layers. In this example, examine the defaults, and click Cancel
to close the Board properties panel.
Note:
More advanced PCB models are covered in the introductory tutorial, RF Amplifier (p. 51),
and the application tutorial, Trace Layer Import for Printed Circuit Boards (p. 347), located
in the Icepak tutorials guide.
• Drilled holes are for positioning purposes and usually are not important to the thermal physics
of the model. During the import, they can be ignored. By default, Ansys Icepak leaves the Import
drilled holes check box deselected under Detailed options group box.
• Select Make all components rectangular under the Detailed options group box to convert all
polygonal components to rectangular prisms.
Figure 15.3: IDF import Panel - Layout options
3. Click Next to go to the Component filters section (Figure 15.4: IDF import Panel - Component fil-
ters (p. 339)). Components can be filtered either by size and power or by component type. For now,
select Filter by components and Import all components. The other options will be explained in
more detail at the end of the tutorial.
Figure 15.4: IDF import Panel - Component filters
4. Click Next to go to the Component models section (Figure 15.5: IDF import Panel - Component
models (p. 340)).
5. Select Model all components as and keep the default settings. The option Choose specific com-
ponent model will be discussed later in the tutorial.
IDF Import
Figure 15.5: IDF import Panel - Component models
6. Click Next to go to the Miscellaneous options section (Figure 15.6: IDF import Panel - Miscellaneous
options (p. 341)). Select Append Part Name to Reference Designator under the Naming conventions
group box.
Figure 15.6: IDF import Panel - Miscellaneous options
7. Click Finish to complete the import.
8. Examine the summary of the IDF import that appears (Figure 15.7: IDF Import Summary (p. 341)).
Click Dismiss to close the panel.
Figure 15.7: IDF Import Summary
9. Examine the imported model (Figure 15.8: IDF Imported Model with All Components (p. 342)).
Observe:
• the different types of blocks
• the material properties of the PCB block (BOARD_OUTLINE.1)
IDF Import
• the power and resistance values of the network blocks, if any
Note that:
• The components form into groups according to types automatically.
• You can use the Edit feature under the Groups node in the Model manager window to
change the properties for all the components in the same group simultaneously.
• Check the text window for missing properties. Any missing values likely originate from the imported
files. You may ignore them in this tutorial since you will not actually run the solver, but you can
define them later if desired.
Figure 15.8: IDF Imported Model with All Components (p. 342) shows the Ansys Icepak model with
components modeled as 3D objects (solid blocks or two-resistor network blocks). Appropriate
boundary conditions need to be applied before starting thermal analysis. In addition, you can review
power values by selecting the Power and temperature limits option in the Model menu.
Figure 15.8: IDF Imported Model with All Components
15.6. Step 3: Component Filtration Alternatives

1. If you choose Filter by size/power (Figure 15.9: IDF Import Panel - Components filters: Filter by
size/power (p. 343)), the size filter and/or power filter may be specified. Only those components that
are either larger than the specified size filter, or dissipate more than the specified power filter, are
imported. If these fields are ignored, all components are imported.
Step 3: Component Filtration Alternatives
Figure 15.9: IDF Import Panel - Components filters: Filter by size/power
2. If Filter by component type is chosen (Figure 15.10: IDF Import Panel - Component filters: Filter by
component type (p. 343)), the required components can be selected through the Component selec-
tion panel (Figure 15.11: Component selection Panel (p. 344)); otherwise all the components are in-
cluded during the import. The Component selection panel contains reference designators for all
components.
Figure 15.10: IDF Import Panel - Component filters: Filter by component type
After clicking Choose, you can choose individual components from the panel in the figure below:
IDF Import
Figure 15.11: Component selection Panel
15.7. Step 4: Component Models Alternatives

1. The Model all components as option is available through both filtration mechanisms.
2. The Choose specific component model option is available when filtering by component type. Ansys
Icepak allows the component property to be added if no thermal information is available from the
IDF file (IDF 2.0), or modify properties if it is available (IDF 3.0).
3. Under Choose specific component model, properties of required components can be loaded from
an existing file using the Load data from file option. The format for the file is:
Reference Power Rjc Rjb

designator (W) (C/W) (C/W)
Figure 15.12: Set Component Property Using File (p. 344) shows a sample file. Objects not present in
the file are imported with data already present in the IDF file, or as solid blocks with no power
specification.
Figure 15.12: Set Component Property Using File
4. Component properties may also be edited manually by selecting the Specify values for individual
component types option. The components to be imported are listed under Selected components.
The component name is composed of the type and name and the number of copies, followed by
a more descriptive part name (Figure 15.13: Manual Selection of Component Models (p. 345)). To
manually set the component property, you can select the component in the Selected components
list. Multiple selections can be made by pressing Ctrl, or Shift, along with the left mouse button.
Then, you can choose the model type: Rjc-Rjb (two resistors), 3d blocks, or 2d sources. Furthermore,
you can specify the power dissipation. For a two-resistor model, Rjc and Rjb values need to be
specified as well. After inputting your specifications, click Apply to complete the modification.
Step 5: Summary
Figure 15.13: Manual Selection of Component Models

You have used the IDF import feature of Ansys Icepak to import a board level model with all of its
components. You observed that the board properties and component properties (where specified) were
automatically updated in the Ansys Icepak model. Last, you have explored the components filtration
and modeling alternatives that are available in the IDF import feature.
Chapter 16: Trace Layer Import for Printed Circuit
Boards
16.1. Introduction
A printed circuit board (PCB) is generally a multi-layered board made of dielectric material and several
layers of copper traces. From the thermal modeling point of view, a PCB may be treated as a homogen-
eous material with bi-directional thermal conductivity, i.e. thermal conductivity value is different in the
normal-to-plane direction than that of the in-plane direction. This approach is reasonable as long as
the trace distribution is more-or-less uniform in any given layer. However, with the continuing challenges
to increase product functionality while decreasing product size, designers are compelled to place more
and more functionality on individual PCB’s. As PCB’s become more densely populated, their trace layers
are becoming more non-uniform and it is prudent to use locally varying thermal conductivity information
on the board.
PCBs often have large copper spread in the power and ground planes, this along with the presence of
vias (especially thermal vias) can be effectively used by the designer to spread heat from the package.
A detailed conductivity map of the PCB is required to simulate heat transfer, which is possible in Ansys
Icepak using the trace import feature.
Conducting a computational heat transfer simulation for each individual layer is costly and impractical
for a system-level model. In Icepak, it is possible to import trace layout of the board and compute locally
varying orthotropic conductivity ( , , , and ) on the board using a profile mesh size. The supported
file formats are:
• ODB++
• EDB
• ANF
• Gerber (for windows only)
• BOOL+INFO
• IPC2581
For trace import licensing and configuration information, refer to Licensing Requirements for Importing
Trace Files in the Icepak User's Guide.
In this tutorial, we will show :
• How to import trace layout of a typical PCB and solve two sample cases based on the trace layout
information.
Trace Layer Import for Printed Circuit Boards
• How to use Model layers separately option for better accuracy.
Note:
16.2. Prerequisites

A PCB board, library files and traces are imported to create the model. The model is first solved for
conduction only, without the components and then solved using the actual components with forced
convection.

3. Specify a name for your project.
a. In the Project name text box, enter the name trace-import.
b. Click Create.

2. Download the traces.zip file here.
3. Unzip the traces.zip file you have downloaded to your working directory.
To build the model, you will first import the board layout. The board and the associated library files
have to be chosen at this step and the trace file can be imported later.
File Import IDF file New
1. In the IDF import panel, select the board (A1.bdf ). Specify the model directory using Browse.
The associated library files are imported automatically.
2. Select Next to see your Layout options. Keep Detail for the Import type, XY for the board plane
and Rectangular for the board shape.
Note:
Because we import the trace information later, we do not need to edit the board properties
at this time.
3. Select Next to see the Component filtering options. Ensure Import all components is selected.
Note:
You can filter certain components at this step by their size and power information, i.e.
you can ignore the small components or the ones dissipating low power. We will import
all of the components in this tutorial.
4. Select Next to see the Component models section. Select Model all components as. Keep the
default selection of 3d blocks and the default Cutoff height for modeling components as 3d
blocks.
Note:
If you have thin components on your board, they can be modeled as 2D sources. In this
tutorial, we would like to model all the components as rectangular blocks.
5. Click Next to go to the Miscellaneous options section where you can specify the naming and
monitor options. Keep the default options and click Finish to start importing the files. This will take
some time depending on the speed of your machine.
You have learned how to import board and library files, and in general you can import any IDF file
by using the procedure above.
The next step in building the model is to import the trace files. A pre-built board model named
"A11" (see Figure 16.1: A11 Board Layout (p. 354)) will be used to demonstrate the trace file import.
This pre-built model was extracted from the previous board file (A11.brd), a number of small com-
ponents were removed and a non-conformal assembly was formed.
a. Unpack A11.tzr file to your desktop and name the project "A11".
Note:
As mentioned earlier, the trace file can either be imported during the IDF file import
or the trace layout information can be assigned to the board after importing the IDF
file.
Figure 16.1: A11 Board Layout
b. Right click BOARD_OUTLINE.1 located in the board assembly in the Model manager window
and click Edit to display the Printed circuit boards object panel.
To import the trace layout, follow the procedures below.
i. In the Geometry tab, select Ansoft Neutral ANF from the Import ECAD file drop down list
(Figure 16.2: Printed circuit boards [BOARD_OUTLINE.1] Panel (p. 355)).
Figure 16.2: Printed circuit boards [BOARD_OUTLINE.1] Panel
ii. Select A1.anf from the Trace file panel. This process may take a few minutes depending on
the speed of your computer.
Note:
A1.anf can be found in the folder containing the input files downloaded for his
tutorial.
iii. Once the import process is completed, you can edit the layer information in the Board layer
and via information panel (Figure 16.3: Importing Trace Layout and Editing Layer Informa-
tion (p. 357)).
The number of layers in the board will automatically be imported to Ansys Icepak and you
will have to enter the thickness of each layer and the material type. In this tutorial, the metal
layers are pure Cu and the dielectric layers are FR-4.
iv. Enter the layer thickness as shown in Table 16.1: Thickness Information on the Board (Layer
1: Top, Layer 7: Bottom layers) (p. 356).
Table 16.1: Thickness Information on the Board (Layer 1: Top, Layer 7: Bottom layers)
Layer Thickness (mm)

Layer 1 0.04
Layer 2 0.45364
Layer 3 0.062
Layer 4 0.467
Layer 5 0.055
Layer 6 0.442
Layer 7 0.045
The grid density is specified By count: or By size:. For highest accuracy, the row and column
sizing should equal the minimum trace width, or minimum via diameter. For coarse mesh
accuracy, we can multiply the minimum trace width by four. For this model, the result is
0.508 mm. Select By size: and change the value of rows and columns to 0.508 mm. For best
practices on accuracy and computational cost, refer to Importing Trace Files in the Icepak
User's Guide.
Figure 16.3: Importing Trace Layout and Editing Layer Information
v. By default, the Model layers separately option is on when importing traces using a pcb
object. Click Update and Done to close the panel. In the Printed circuit boards
[BOARD_OUTLINE.1] panel, click Edit... across from Trace layers and vias to display the
Board layer and via information panel. The Model layers separately option is on. Click
the Don’t recompute metal fractions option to turn it off.
vi. Via information (for example, material, plating thickness, filled/un-filled, via diameter etc.) is
imported automatically (Figure 16.4: Vias Information (p. 358)), keep the default settings.
Figure 16.4: Vias Information
vii. Click Update and Done to save your settings.
Note:
The background mesh matrix (rows and columns) is used to compute the ortho-
tropic conductivity on the board. The rows represent the division of the board in
the y-direction, the columns represent the division of the board in the x-direction
and the size field determines the divisions of the board and indicates the grid size
in each direction. The values of , , , and on each cell are determined by
the local trace density and the direction. Ansys Icepak does not include the trace
geometry in the physical model; however, the locally varying orthotropic conduct-
ivity is mapped from the background mesh to the physical model mesh. Once the
trace file is imported and assigned to the board geometry, the trace layers are
associated with the board and are moved (in translation and/or rotation) with the
board object.
viii.Press Done to close the Printed circuit boards object panel.
ix. Right click on the object BOARD_OUTLINE.1 and go to Traces from the menu.
Note:
You can view the traces in three different ways, i.e. single color, color by layer,
or color by trace. Each of the trace layers can be viewed separately by switching
the visible option on or off in the layers part of the panel. (Figure 16.5: Displaying
Traces on the Board (p. 359)).
Figure 16.5: Displaying Traces on the Board
x. Select color by trace; the board traces are as shown in Figure 16.6: Trace Layout on the PCB
with the Color by trace Option (p. 360).
Figure 16.6: Trace Layout on the PCB with the Color by trace Option
You can view the location of individual trace layers as shown in Figure 16.7: Displaying Trace
Layers (p. 360) by enabling the Display traces in 3D option in the Preferences panel.
Edit Preferences Display
After enabling Display traces in 3D option, select This project in the Preferences panel,
zoom in and display the positive Y view of your model.
Figure 16.7: Displaying Trace Layers
xi. View the fraction of metal traces based on the grid density entered above. Go to the Model
menu and select Show metal fractions. In the Show metal fractions panel, select
BOARD_OUTLINE.1 across from Object with traces. The other fields will be automatically
filled with the PCB information.
Figure 16.8: Metal fractions display
Click Close to go back to your previous display.
16.6. Conduction Only Model (PCB Without the Components)

Follow these steps for a conduction-only model:

You will generate a mesh for each sample problem. First we will consider a board without any compon-
ents.
1. Make all objects (including the openings) inactive except the BOARD_OUTLINE.1 object.
2. Select the cabinet and select Autoscale from the Edit window to make the size of the board and
the cabinet the same.
3. Go to the Properties tab of the Cabinet object panel, and select Wall from the Min z and Max z
drop-down lists.
4. Press Edit next to Min z to open the Walls object panel.
a. In the Properties tab, select Temperature from the External conditions drop-down list, and
keep the ambient temperature (20°C).
b. Press Done to close the panel.
5. Press Edit next to Max z to open the Walls object panel.
a. In the Properties tab, specify a Heat flux of 20000 W/m2 in the Thermal specification group
box.
Note:
The rest of the sides are insulated. The board will be simulated using a conduction-only
model.
6. Press Done to close the Cabinet panel.
7. Go to Model Generate mesh to open the Mesh control panel.
a. Make sure the Mesh type is Mesher-HD.
b. Specify a Max element size for X, Y, and Z as 2.032, 2.032, and 0.05 mm respectively, and a
Minimum gap for X, Y, and Z as 1, 1, and 0.01 mm respectively.
Note:
To achieve accurate results, the PCB mesh and gridcut mesh should be refined
at the same rate. A good balance of cost and accuracy is achieved when the PCB
mesh is four times the gridcut mesh. For this model, that leads to 2.032 mm in
the X and Y directions.
c. Keep all other defaults and click Generate.
8. Once the mesh has been created, Close the Mesh control panel.
16.8. Step 2: Set Physical and Numerical Values

a. Since this is a conduction only model, toggle off the Flow option in the General setup tab.
b. Make sure Radiation is off and keep all other default values.
c. Press Accept to close the Basic parameters panel.
a. Keep the default Number of iterations and set the Convergence criteria for Energy to 1e-12.
b. Click Accept to close the panel.
a. Input the following for Temperature in the Linear solver group box:
i. Make sure F cycle is selected for Type .
ii. Enter 1e-6 for both the Termination criterion and Residual reduction tolerance.
b. Select Double for the solver Precision.
c. Press Accept to close the Advanced solver setup panel.

File Save project
Go to Solve Run solution or click on the shortcut button ( ). Enter a Solution ID such as A11–0.508.
Start the solver by clicking Start solution.

1. Once the model has converged, Activate cut.1 if not already activated.
2. Edit cut.1 and make sure that Set position is Point and normal.
3. Make sure that PX, PY, PZ are 0, 0, and 0.78232, respectively and the NX, NY, and NZ are 0, 0, and
1, respectively.
4. Press Done and view the model.
The mid-plane temperature distribution shows that the high temperature regions occur at the no-trace
areas and low temperature regions occur at areas with a high trace concentration. This is expected as
the copper content is directly proportional to the trace concentration. It is worth noting that if a compact
or detailed PCB were used in lieu of the traced PCB, one would obtain a fixed temperature for the entire
mid-plane and this fixed temperature would be different from the average temperature of the traced
PCB on the same plane.
Figure 16.9: Temperature Distribution on the PCB (mid-plane)
Note:
The spatially varying non-uniform conductivity of the board can also be viewed during post
processing. The conductivities in the three direction , , and are available as post-
processing variables with plane cuts and object faces. Figure 16.10: K_Z Distribution on the
PCB (mid-plane) (p. 365) plots at the board mid-plane by selecting K_Z from the Contours
of drop-down list from Plane cut contours panel of the cut.1 object. In the present case,
because the layers are modeled separately, there is a variation of the conductivities in the
board-normal direction.
Figure 16.10: K_Z Distribution on the PCB (mid-plane)
16.12. PCB With the Actual Components Under Forced Convection

Follow these steps for a model that has components:

1. In order to put the actual components back into the model, highlight all the components under the
Inactive folder and drag them back into the Model folder. Highlight the two wall objects created
for the "conduction only" model and drag them into the Inactive folder.
2. Click on the Cabinet and Autoscale it from the Edit window.
3. If not already defined, assign an X Velocity of -1.5 m/s in the Properties tab of the Openings
panel for the Max x side of the cabinet (the minus sign shows that the flow is in the negative x
direction).
4. Open the Mesh control panel and specify a Max element size for X, Y, Z as 9.5, 7, and 0.7 mm re-
spectively.
5. Keep all other defaults and Generate the mesh.
16.14. Step 2: Set Physical and Numerical Values

1. Since we now have forced convection, go to Problem Setup Basic parameters toggle on
the Flow button. Keep and choose Turbulent and Zero equation for the flow regime and press
Accept to close the panel.
2. Go to Solution settings Basic settings and make sure the Number of iterations is 300
and that the Convergence criteria are the same as the last mode, and press Accept to close the
panel.
3. Keep the same Advanced settings as the previous case.

Click Solve Run Solution to display the Solve panel. Enter a different solution id for the forced
convection model (that is, A11-conv). Enable Sequential solution of flow and energy equations and
click Start solution.

To display contours of temperature on the board, follow the procedures below.
1. Once the model has converged, deactivate cut.1 and go to Post Object Face.
2. Select BOARD_OUTLINE.1 from the Object drop-down list.
3. Turn on the show contours and click on Parameters button.
4. Keep the default selection of Temperature.
5. For Color levels, select This object from the drop-down list.
6. Press Done in the Object face contours panel and then the Object face panel to view the postpro-
cessing object.
This shows the temperature distribution at the top of the surface of the board (Figure 16.11: Top
Surface Temperature Distribution: PCB With Imported Traces in Forced Convection (p. 367)). There
are hot spots underneath the high heat flux components.
Additional Exercise 1
Figure 16.11: Top Surface Temperature Distribution: PCB With Imported Traces in Forced
Convection
7. Deactivate the face.1 postprocessing object.
16.17. Summary
In this tutorial, you imported the board layout and trace files. Then you simulated the board using a
conduction only model using a grid density by size of 0.508 mm for rows and columns. Postprocessing
this model showed high temperature regions occurring at the no-trace areas and low temperature regions
occurring at areas with a high trace concentration. Then you simulated the board with the components
put back into the model and simulated under forced convection.
16.18. Additional Exercise 1

Using this model, you can determine the joule/trace heating of the imported traces. This problem is
described in Tutorial Joule/Trace Heating (p. 369).
Chapter 17: Joule/Trace Heating
17.1. Introduction
In the tutorial (Trace layer Imports for Printed Circuit Boards (p. 347)), you learned how to import a trace
layout of a typical PCB using the ANF format and also learned how to model the trace layers separately
for better modeling accuracy. In this tutorial, you will learn how to model resistive heating or Joule
heating of the imported traces in the PCB.
Since PCB traces have electrical resistance, they heat up as current flows through them. Modeling this
phenomenon will provide us with an accurate prediction of the temperature distribution in the PCB,
which can be important, for example, in evaluating the performance of the cooling system.
Note:
17.2. Prerequisites
This tutorial assumes that you have completed the tutorial Trace layer Imports for Printed Circuit
Boards (p. 347) of this guide. This same model is used to determine the Joule/trace heating capability
in Ansys Icepak.

The model in the tutorial Trace layer Imports for Printed Circuit Boards (p. 347) contains imported traces
and will be used in this tutorial. You will determine the Joule/trace heating capacity of the traces.

2. Download the joule_heating.zip file here.
3. Unzip the joule_heating.zip file you have downloaded to your working directory.
Joule/Trace Heating
4. Start Ansys Icepak, as described in Chapter 1 of the User’s Guide.
Note:
When Ansys Icepak starts, the Welcome to Icepak panel will open automatically.
5. Click Unpack in the Welcome to Icepak panel to start a new Ansys Icepak project.
Note:
The File selection panel will appear.
6. In the File selection panel, select the packed project file joule-heating.tzr (found in your
working folder) and click Open.
7. In the Location for the unpacked project panel, select a directory where you would like to place
the packed project file, enter a project name in the New Project text field, and click Unpack.

Import the traces using A1.anf and change the thickness as described below. Keep the default values
for Grid density.
Table 17.1: Thickness Information on the Board (Layer 1: Top, Layer 7: Bottom layers)

Layer 1 0.04
Layer 2 0.45364
Layer 3 0.062
Layer 4 0.467
Layer 5 0.055
Layer 6 0.442
Layer 7 0.045
You will work directly on the Joule heating capability in Ansys Icepak
1. Select BOARD_OUTLINE.1 from the Model manager window.
a. Right click on the object BOARD_OUTLINE.1 and click on Traces in the context menu. You can
view the traces in three different ways and select Off to remove the display.
b. You can also view individual traces or nets by selecting Traces from the View menu and clicking
on Trace info. As you click on different areas in the graphics display window, the trace name
and number will appear. Click on the right or middle mouse button when you are done. In the
steps below, you will create a solid trace from one of these traces.
c. Open the BOARD_OUTLINE.1 edit panel. In the Geometry tab, click the Edit button next to
Model trace heating. The Trace heating panel opens.
i. In the drop-down list under Layers, select INT1_3. The list in the Display traces group box
shows available traces. You can filter the traces to view by setting a Min Area in the Display
traces filter group box (the default in Ansys Icepak is 20% of the Largest trace area) and
clicking the Update button. In this example, use an Min Area of 4124 mm2, as this will only
show the significant traces.
Note:
The “trace area” of a trace is the area interior to that trace. The Trace heating
panel lists the traces in each layer in order of descending area, see Figure 17.1: Trace
Heating Panel Selection and Options (p. 372).
ii. Before you create a solid trace of trace A3V3_2261 (the appended number, in this case
2261, may vary), you need to modify the Max angle and the Min length to ignore the fine
details in the trace geometry and reduce the mesh count. If you have not done so already,
select trace A3V3_2261 and set the Max angle filter to 135 and the Min length filter to
1.0 mm. These settings determine the creation and geometry of a trace block modeling the
trace.
Joule/Trace Heating
Figure 17.1: Trace Heating Panel Selection and Options
iii. Click the Create solid trace button. Ansys Icepak will create a polygonal solid block named
BOARD_OUTLINE.layer-3-trace-A3V3_2261 that contains the trace information. (The
actual name may vary). Click Done to close the Trace heating panel.
Note:
You can try reducing the Area filter to 1000 mm2 to check how many traces
appear. We are interested in the largest trace, trace A3V3_2261.
d. Click Done in the Printed circuit boards panel to close the panel and view the model ). Note
that the shaded object in the figure below is the block you have just created for trace
A3V3_2261.
Figure 17.2: Solid Block Created for Trace A3V3_2261
2. Select the polygonal trace just created from the Model manager window and open the Blocks
panel.
a. In the Geometry tab of the Blocks panel, make sure there are approximately 184 vertices for
the trace, as shown in Figure 17.3: Polygonal Trace Block (p. 374).
Joule/Trace Heating
Figure 17.3: Polygonal Trace Block
b. Go to the Properties tab.
i. Under Thermal specification next to Joule heating, click Edit to open the Joule heating
power panel.
A. Make sure the Resistivity, temperature coefficient (C), and reference temperature (Tref)
are set as in Figure 17.4: Joule Heating Power Panel (p. 375).
Note:
These values differ by material type. The values shown represent annealed
copper.
B. Make sure the Properties tab of the Blocks panel looks like those in Figure 17.4: Joule
Heating Power Panel (p. 375).
C. Press Done in the Joule heating power panel and then in the Blocks panel.
Figure 17.4: Joule Heating Power Panel
ii. Create two source objects on the BOARD_OUTLINE as shown in Figure 17.5: Source Geometry
Definitions (p. 376).
Joule/Trace Heating
Figure 17.5: Source Geometry Definitions
• One source is for the current source (source.1) and the other for the voltage source
(source.2).
• Both sources are created at the same layer as the layer of the wire in. The area of the each
source is the area to apply the voltage or the current.
• The recommendation of the source objects pair for joule heating is current-voltage pair
or voltage-voltage pair.
iii. Apply a current specification of 25 Amps to source.1 and a voltage specification of 0 V to

source.2 as shown in Figure 17.7: Source Geometry Definitions (p. 377). The current runs
from source.1 through source.2.

1. Create a non-conformal assembly for the trace. Since we are performing a joule heating calculation,
it is necessary to have a high or medium mesh quality in case the joule heating calculation diverges.
To create high quality mesh, we will create an assembly with the 3D trace geometry and set a small
element size.
a. Select the BOARD_OUTLINE.1.layer-3-trace-A3V3_2261, source.1, and source.2

objects, right-click on them, and go to Create and then Assembly.
Note:
The mesh priority of the trace block must be greater than the mesh priority of the
PCB.
b. Double-click the assembly you created to open the Assemblies panel.
i. In the Meshing tab, select Mesh separately and input the Slack settings, Mesh type, Max
element size, Min gap and Global specifications settings as shown in Figure 17.8: Mesh
Settings for the Trace Board (p. 378).
Joule/Trace Heating
Figure 17.8: Mesh Settings for the Trace Board
Note:
Ensure the Mesh type is Mesher-HD.
c. Press Done to close the Assemblies panel.
a. Ensure that your settings match those in Figure 17.9: Mesh control Panel (p. 379).
b. Click Generate to create the mesh.
c. Check the mesh quality for the trace and the overall model from the Display and Quality tabs.
Joule/Trace Heating

1. Double-click the cabinet_default_side_maxx object in the Model manager window to open
the Openings panel.
a. In the Properties tab, ensure the X Velocity is -1.5 m/s.
Note:
Model manager window. See 2.7. Step 4: Physical and Numerical Settings (p. 28) of the
a. Since this is a forced convection problem, ensure that the Flow and Temperature check boxes
and the Turbulent option are selected. Select Zero equation as the turbulence model.
a. Make sure the Convergence criteria for Flow is 0.001.
b. Set the Number of iterations to 200 and the Convergence criteria for Energy and Joule
heating to 1e-8.
c. Press Accept to close the panel.
i. Choose F cycle from the Type drop-down list.
iii. Ensure that BCGSTAB is chosen as the Stabilization criterion for both Temperature and
Joule Heating Potential.
b. Make sure the Precision for the solver is Double.
Your settings should match those in Figure 17.10: Linear Solver Settings (p. 381).
Figure 17.10: Linear Solver Settings
c. Press Accept to close the Advanced solver setup panel.

idea to save the model (including the mesh) yourself as well.
File Save Project

1. Click Solve Run Solution.
2. Click Start solution.
3. After your solution has converged, your residuals plot may look similar to Figure 17.11: Solution
Residuals (p. 382).
Joule/Trace Heating
Figure 17.11: Solution Residuals

Once the model has converged, create an object face.
1. Double click on the object cut.1 under post processing and click on the check box next to Active
to deactivate it.
2. Select the trace and show the temperature contours.
a. Go to Post Object face.
b. In the Object drop-down list, select the trace (BOARD_OUTLINE.1.layer-3-trace-

A3V3_2261).
c. Select Show contours and click Parameters. In the Object face contours panel, select Temper-
ature in the Contours of drop-down list and select This object next to Calculated in the Color
levels group box. Click Apply.
d. Observe the trend of the temperature contour and how it varies from one side to other, and
compare the maximum temperature for the cases with and without trace modeling (Fig-
ure 17.12: Trace Temperature Contours with Forced Convection (p. 384)).
Joule/Trace Heating
Figure 17.12: Trace Temperature Contours with Forced Convection
3. Now plot the electric potential of the same trace, Figure 17.13: Trace Electric Potential Contours with
Forced Convection (p. 385).
Figure 17.13: Trace Electric Potential Contours with Forced Convection
a. Click Parameters to open the Object face contours panel.
b. Select Electric Potential from the Contours of drop-down list and press Apply.
c. Observe the contours.
• Do you observe any similarity between the temperature and the electric potential contours?
• The temperature contours are closely related to the electric potential contours, which is a
direct result of Joule heating of the trace.
Joule/Trace Heating
d. Press Done in the Object face contours and Object face panels to close the panels.

In the previous tutorial, Trace Layer Import for Printed Circuit Boards (p. 347), you learned how to import
trace layers for a PCB and how to model them with various degrees of accuracy and detail. In this tu-
torial, you have learned how to filter traces by their geometry and to model the Joule heating or resistive
heating of desired traces in Ansys Icepak. This method allows you to determine an accurate prediction
of the temperature distribution in a PCB.
We repeat some of the best practices found in this tutorial for your convenience:
• Filter out traces too small to be thermally significant. This can reduce unnecessary meshing and
computational time.
• Check for current conservation manually.
• Use the hex-dominant mesher when you are using imported trace data.
Chapter 18: Microelectronics Packages - Compact
models
18.1. Introduction
This tutorial is a case study of a board design. A card supplier is making two package type changes to
an existing commercial board. The objective of the thermal simulation project is to see if the selected
new packages are likely to function without overheating. In the event of over heating, what kind of
thermal management should be recommended?
• Perform a board level simulation with appropriate package models.
• Determine if the selected new packages can function without overheating.
Note:
18.2. Prerequisites
This tutorial assumes that you have worked on Sample Session in the Icepak User’s Guide and the first
two Ansys Icepak tutorials of this guide.

A designer is to select packages for a new design at the drawing board level. Available information
about the board and packages is given. Determine cooling solutions in the event there is overheating.
Microelectronics Packages - Compact models

2. Download the compact_package.zip file here.
3. Unzip the compact_package.zip file you have downloaded to your working directory.
4. Copy the file compact-package-modeling.tzr to your working directory.
7. In the File selection panel, select the packed project file compact-package-modeling.tzr
and click Open.
like to place the packed project file, enter a project name, such as test-1, in the New project
text field then click Unpack.

This tutorial uses an existing model. Ansys Icepak will display the model in the graphics window as
shown in Figure 18.2: Layout of the board to be analyzed (p. 389). Available information about the board
and packages is shown in Table 18.1: Available Details for Objects in the Model (p. 389) and
Table 18.2: Available Information for 400 PBGA (p. 390). During the procedure, you will use these tables
to edit existing objects and as well as to create new objects.
Figure 18.2: Layout of the board to be analyzed
Table 18.1: Available Details for Objects in the Model
Object Number of Available Information Power

Occurrences (W)
in Model
PCB 1 1.6 mm thick, FR4 Material, six 1 oz. 0
layers of Copper, 30% coverage for all
layers
Heat Spreader for TO-220 3 Al-Extruded 0
packages
TO-220 Packages 9 = 2.5° C/W 1.5
DIP 6 None 0.5

400 PBGA (new package type to 6 See Table 18.2: Available Information for 2.0
the existing board) 400 PBGA (p. 390)
Object Number of Available Information Power

Occurrences (W)
in Model
232 PQFP (new package type to 2 232 leads, 40 mm X 40 mm Footprint, 2 3.5
the existing board) mm height
Note:
An ounce of Copper is actually the thickness of 1 ounce/sq.ft of plane copper sheet. Using
copper density this translates to a thickness of 0.035 mm.
Table 18.2: Available Information for 400 PBGA
Feature Size (mm) Material/Conductivity Other info Where to input this

(W/mK) info
Overall 26 x 26 x 2.15 Dimensions tab
package
Mold 0.8 Die/Mold tab
compound
Die 18 x 18 x 0.4 Silicon material Die/Mold tab
Die Flag 18 x 18 x 0.035 80.0 (effective) Die/Mold tab
(equivalent)
Die Attach 0.05 mm thick Not mentioned Die/Mold tab
Substrate 0.4 mm thick FR4 Substrate tab
Substrate 0.035 mm thick Copper 4 layers, top and Substrate tab
traces bottom 30%
coverage
intermediate layers
are 100% (plane
layers)
Vias Unknown Not mentioned Number of vias Substrate tab (use 0
unknown for vias)
Solder Balls Standard Solder 20 x 20 count, full Solder tab
array
Wire Bonds Not mentioned Usually Gold Die/Mold tab
1. Create the PCB.
Create a PCB object by clicking the Create printed circuit boards button ( ). Then edit the PCB
by clicking the Edit object button ( ) while the PCB object is selected in the Model manager
window. Enter the following in the Geometry tab:
Object type Name Shape/Type/Plane Global Coordinates (m)
XS— YS— ZS— XE— YE— ZE

PCB pcb.1 X-Z 0.0 — 0.0 — 0.0— 0.25— N/A— 0.2
a. Go to the Properties tab. Enter the PCB thickness of 1.6 mm for Substrate thickness.
b. Change the default unit from microns to Cu-oz/ft2 for high and low surface thickness and for
internal layer thickness under the Trace layer parameters group box.
2. Enter the material information for the PCB found in Table 18.1: Available Details for Objects in the
Model (p. 389). This information can be entered for the selected PCB object as shown in Fig-
ure 18.3: PCB Edit Form with input based on PCB information in the Table with Model Object Details
above (p. 391).
Figure 18.3: PCB Edit Form with input based on PCB information in the Table with Model
Object Details above
Now, you should see the PCB object overlapping the block called PCB. There is no more need for
this block.
Note:
You recreated the PCB object geometry using coordinates of the imported PCB block.
3. Right-click the block named PCB and deselect Active to deactivate the block object.
4. Verify the material properties of the heat spreaders for the TO-220 devices.
a. Since the default solid material happens to be Al-Extruded, all three spreaders should have
come into the model with the correct material specifications. Check this information by editing
the spreaders.
5. Model the packages.
This model has four different types of objects. Based on the available information and our objectives,
we shall use different compact package modeling capabilities in Ansys Icepak.
a. TO-220 type packages
i. There are 9 TO-220 device blocks. Select them all at once by drawing a selection box around
them with Shift and the left mouse button (see Figure 18.4: Window Selecting Multiple Objects
for Simultaneous Edit (p. 393)). Press Shift+y to get a positive Y orientated view as in the
figure. Simultaneous selection can also be done in the Model manager window. Press the
Ctrl key and click to select several objects.
Figure 18.4: Window Selecting Multiple Objects for Simultaneous Edit
ii. You should see all TO-220 devices highlighted in the Model manager window. Note that
only TO-220 objects should be selected. If you see other objects highlighted (such as the
Spreader objects), deselect them by holding down the Ctrl key and clicking them in the
Model manager window. You can simultaneously edit all of the remaining objects at once
by right-clicking on any one of the selected TO-220 objects in the Model manager window.
Caution:
You will not be able to edit the objects simultaneously if you still have the
spreaders selected.
A. Select Network for the Block type.
B. Keep the default selection of Two resistor for the Network type.
C. In order to assign the resistance, you need to identify a reference side. This is the purpose
of the "board side" input. You want the resistance to be applied from the junction to the
side in contact with the spreader (Max Z side). You can accomplish this in two ways:
• Designate Min Z as the Board side and assign the supplier provided resistance value
(2.5 C/W from Table 18.1: Available Details for Objects in the Model (p. 389)) to Rjc.
or
• Designate Max Z as the Board side and assign the supplier provided resistance value
to Rjb.
Note:
Zero resistance means that there would not be any link and the resistance
values are infinite. For more information regarding the two-resistor model,
refer to Two-Resistor Model in the Icepak User’s Guide.
D. Input 1.5 W for the Junction power.
Figure 18.5: TO-220 Properties Tab
iii. Click Done to finish the operation.
b. DIP type packages
i. As you have done previously for the TO_220 objects, select all the DIP objects and simultan-
eously edit them.
ii. Select default for Solid material (however, any material would work because you are not
interested in the temperature of the DIP packages).
A. Input 0.5 W in the Total Power field.
B. Click Done.
Note:
DIP is the package type for which you have the least information. So you are
left with two options:
• Try to get additional information from the supplier.
or
• Perform a tentative simulation with the available information. The options

are considered along with the following facts:
– The DIPs contribute a lower heat flux than the other components in the
board.
– This is an existing design in which the DIPs have been known to run well
below their specified temperature even at max power.
Based on the above reasoning, it is easier to perform a tentative simulation

with the available power information than to obtain additional information
from the supplier. In this context the purpose of the DIP package modeling is
to appropriately account for air and PCB heating due to flow over the DIPs.
Accurate prediction of the DIP-package temperature is therefore not an object-
ive.
c. PQFP type packages
Internal details are unavailable for the PQFP type package. But based on the exterior details
such as lead count, foot print size, and package height information, it is possible to construct a
compact model of a typical package for screening analysis.
i. Go to the Libraries node by clicking the Library tab in the Model manager window. Right-
click Libraries and select Search packages.
Note:
A package may also be created using either IC package macros or a package object.
ii. In the Search package library panel enter all known information about the package
(Table 18.1: Available Details for Objects in the Model (p. 389)) as the search criteria. Clicking
the Search button should return [1] the closest matching packages from the library. Pick the
package that is most similar in description to the 232-lead PQFP information available and
select Create. Figure 18.6: Package Search Criteria (p. 396) depicts the package search settings
and results.
Figure 18.6: Package Search Criteria
[1] If search does not return a relevant package, click the package object icon to create a new
package object. After entering the few known values, you may enter reasonable values or
leave the remaining parameters as default.
iii. Go back to the Project tab and edit the newly created package object. Make sure that:
• The Package type is QFP.
• The Package thickness is 2.0 mm.
• The Model type is Compact Conduction Model (CCM).
• The Symmetry is Full.
Note:
CCM is a compact model based on geometric simplifications that still preserve the
original heat transfer pathways of the package. It has been demonstrated [2] that
CCM is fairly accurate and boundary condition independent. Other options under
Model type are:
• To model the package in full detail. This option is meant for package level
modeling. Using this in board or system design will create many more objects
requiring meshing and thus increase the mesh size.
• To characterize junction-to-case and junction-to-board network resistances for

a two resistance compact model. We have used this for the PBGA package.
iv. Select the Die/Mold tab. (The Substrate and Solder tabs show blank interface since QFP
type packages do not have soldering or substrates.) Enter 3.5 W for Total power.
v. Use all other defaults under the Die/Mold tab. Click Done to close the tab.
vi. The package created is in an arbitrary location. You may use the Align face centers button
( ) to position the base center of the created package object with that of the 232PQFP
block. The dimensions of the package should match the dimensions of the 232PQFP block
(select the block to see its dimensions):
vii. Since there is no more need for the 232PQFP block, deactivate it.
viii.There is another 232PQFP block (232PQFP.1). Create a copy of the first package object and
align it with the remaining 232PQFP block. Note that this second package is offset from the
first in only the X direction by –70 mm. Deactivate the second "232PQFP" block (232PQFP.1).
The dimensions of the second package should be:
[2] Karimanal, K.V. and Refai-Ahmed, G., "Validation of Compact Conduction Models of BGA
Under An Expanded Boundary Condition Set", Proceedings of the ITHERM 2002, May 2002,
San Diego, Ca, USA.
d. PBGA type packages
You have fairly comprehensive information about the PBGA type package from the supplier (see
Table 18.2: Available Information for 400 PBGA (p. 390)). Using this information you can construct
a CCM or characterize to determine Θjc and Θjb to model it as a two-resistor network model as
shown here:
i. Select all the blocks named 400-PBGA and edit all of them simultaneously.
A. Select Network as the Block type and Two resistor as the Network type.
B. Set the board side as Min Y.
C. Input the estimated Θjc (1.4 C/W) and Θjb (6.75 C/W) values in the Rjc and Rjb fields
respectively.
D. Input a Junction power of 2.0 W.
E. Click Done to finish.
ii. Edit the Cabinet. In the Properties tab, you have the option to define the boundary condition
(Wall type) for each side of the cabinet. Set the Wall type for Min x and Max x as Opening.
iii. Press Edit for the Min x side to open the Openings panel.
iv. In the Properties tab of the Openings panel, assign an X velocity of 1.0 m/s.
v. Click Done to close the Openings panel.
vi. The Max x side opening should have the default settings (free opening).
vii. All other cabinet boundaries should be Default.
viii.Click Done in the Cabinet panel to confirm changes.
ix. You should see the openings on the min X and max X sides of the cabinet.
1. Click the mesh icon .
a. Make sure Mesher-HD is selected as the Mesh type and Normal is selected for Mesh
parameters.
b. Click Generate to create the mesh.
Figure 18.7: Mesh control panel
c. Evaluate your mesh from the Display and Quality tabs.
2. (optional) Create non-conformal assemblies around each package set to reduce mesh bleeding and
consequently reduce the mesh count. As a start, use 3 mm slack values for all sides of each assembly.
Resize the assemblies if necessary. With non-conformal assemblies, you can reduce the number of
elements in the mesh significantly. Display and compare the conformal and non-conformal meshes.

1. Go to Problem setup Basic parameters and set the Flow regime to Turbulent in the
General setup tab.
Click Accept to close the panel.
2. Go to Solution settings Basic settings panel and click Reset. Set the number of iterations
to 200 in the Basic settings panel and close the panel by clicking Accept.

Save the model after the model building and meshing is complete.
File Save project

1. Define monitor points of temperature for the 232-Lead_PQFP_40mmX40mm package and DIP
object. A monitor point will be created to monitor the temperature change with iterations (Fig-
ure 18.8: Monitor Point Definition (p. 402)).
Figure 18.8: Monitor Point Definition
2. Go to Solve Run solution and select Sequential solution of flow and energy equations. Since
you have neglected gravity, there is no coupling between the flow and energy equations. Therefore,
sequential solution of the flow and energy equations is possible to speed up the convergence rate.
Figure 18.9: Solve panel

First observe the general temperature distribution pattern on the board.
1. Create temperature contours of pcb.1 by clicking the Object face icon ( ), selecting Show contours,
clicking Parameters, and selecting This object for the Calculated drop-down list. Figure 18.10: Tem-
perature Contours on pcb.1 (p. 404) depicts the object face you have just created.
Figure 18.10: Temperature Contours on pcb.1
• Probe temperatures values at desired locations on the object face by using the Surface probe
feature ( ).
• Note the higher temperatures in the parts of the PCB under the PQFP packages.
2. Go to Report Network block values. The text window lists all the network block temperatures.
Network junction temperatures can also be obtained from the overview report.
3. The closeness of the PBGA objects relative to each other may be a potential cause for overheating.
How much of the problem is due to the ambient temperature of the air flowing past these compon-
ents?
• You can visualize the thermal boundary layer over the PBGA objects by taking an X-Y plane cut
of temperature contours over the PBGA blocks (Figure 18.11: Temperature Contour Plane Cut (Z
plane through center) (p. 405)). Note the higher temperatures in the wake region of the right-most
block.
Figure 18.11: Temperature Contour Plane Cut (Z plane through center)
4. What is the cause for the relatively high temperatures of the TO-220 devices?
• Are the heat spreaders too close? If so, the air flowing between the spreaders will overheat pre-
venting further heat dissipation to the air. You can find out if this is the case by creating XZ cut
planes of vectors and contours that cut across the spreader blocks. In Figure 18.12: Temperature
Contour Plane Cut (Y plane through center) (p. 406), the boundary layers of the spreaders do not
interfere with each other significantly. Therefore, their arrangement relative to each other is not
problematic thermally.
Figure 18.12: Temperature Contour Plane Cut (Y plane through center)
5. The highest temperatures are in the 400-PBGA blocks. Effective cooling solutions can be designed
by understanding heat flow pathways.
• Generate a summary report of heat flow for the 400-PBGA blocks. By deselecting the check box
under Comb in the Define summary report panel, generate an itemization of the heat flow
through each side of the object. Figure 18.13: Summary Report for Object 400-PBGA (p. 407) shows
the resulting summary report.
Figure 18.13: Summary Report for Object 400-PBGA

In this tutorial, you performed a board level simulation and determined cooling solutions in the event
there is overheating. In addition, you learned how to specify properties of PCBs, packages, and network
blocks to model your system more accurately than possible with only block objects.

Post-processing showed that the components of 400-PBGA are the most critical objects since they are
the hottest. Here are some cooling ideas to set up and perform Ansys Icepak simulations:
What if:
1. The flow is in the negative X direction?
2. The flow is in the negative X direction, and by judicious use of flow resistances, more flow is diverted
toward the PBGA objects (for the same overall flow rate)?
3. The bottom side of the PCB is not dissipating any heat as a result of lying on a domain boundary.
On the other hand, there seems to be plenty of space above the board. The main reason for the
headroom above the PCB is the height of the spreader blocks. While there is room to move up the
spreader by a little bit, more room can be gained if the spreader is longer in the X direction but
shorter in its Y height. What if both sides of the PCB are exposed to airflow by moving the PCB up-
ward?
4. A heatsink is mounted on the PBGA blocks? Will it be possible to use a heatsink in contact with all
PBGA blocks? Are there any practical issues?
Chapter 19: Multi-Level Meshing
19.1. Objective
The objective of this exercise is to use multi-level meshing to improve the mesh resolution and optimize
the mesh count of a model that has CAD objects. The procedure from this exercise should help you
make adequate modeling and meshing decisions during your thermal modeling projects.
Note:
19.2. Prerequisites
The trainee should be familiar with:
• Ansys Icepak modeling objects
• Basics of meshing
19.3. Skills Covered

• Basic meshing techniques
• Multi-level meshing
• Uniform mesh parameters option
19.4. Loading the Model

2. Download the hanging_node.zip file here.
3. Unzip the hanging_node.zip file you have downloaded to your working directory.
4. Unpack and load the model named HangingNode.tzr.
Multi-Level Meshing
5. Go to File Save project as.
• Rename the project to any name of your choice.
19.5. Step-by-Step Approach

Without any modifications, the model results in about 700,000 elements. Note that this mesh count
results from using the non-conformal meshing technique, which reduces mesh bleeding and mesh
count. However, this mesh does not fully resolve the fine-level geometric features of the CAD objects.
You can reduce the mesh count and improve the mesh resolution on and around the CAD objects by
using the multi-level meshing technique. This procedure starts with a coarse background mesh and
resolves fine level features through a series of successive mesh refinements. By using multi-level
meshing and the uniform mesh parameters feature, you can reduce the mesh count to approximately
500,000 elements and improve mesh resolution.
Note:
Multi-level meshing allows for gradually increasing resolution of fine-level features. For more
information on multi-level meshing, see Meshing Options of the Icepak User’s Guide.
• Generate the mesh without modifying the model. You will see a mesh count of about 700,000 cells.
Note:
The mesh count may differ slightly on different machines.
Step-by-Step Approach
Multi-Level Meshing
Figure 19.1: Mesh of Flow Guide Without Multi-Level Meshing
Modification 1: Multi-Level Meshing of the Fan_Guide
Figure 19.2: Mesh of Sheetmetal_HS Without Multi-Level Meshing
19.6. Modification 1: Multi-Level Meshing of the Fan_Guide

• In the Meshing tab of the fan_guide.1 assembly, retain the slack and minimum gap values.
However, change the Max element size values to 4.0 mm.
• In the Options tab, select Set uniform mesh params and retain the selection of Use average.
• In the Multi-level tab, select Allow multi-level meshing and set Max Levels to 0. Click Edit levels
to open the Multi-level meshing max levels panel, and enter a value of 2 for FLOW_GUIDE5411.1
and guide_rect-0.3.
• Keep the default selection of Proximity size function and Curvature size function.
Note:
For more information on various multi-level meshing options, see Global Refinement for
a Hex-Dominant Mesh of the Icepak User’s Guide.
Multi-Level Meshing
19.7. Modification 2: Multi-Level Mesh of the Sheetmetal_hs_assy.1

• In the Meshing tab of the Sheetmetal_hs_assy.1, retain the slack and minimum gap values.
However, change the Max element size values to 3.5 mm.
• Select Set uniform mesh params and retain the selection of Use average.
Generate a Mesh
• In the Multi-level tab, toggle Allow multi-level meshing, set Max Levels as 3, and set Buffer layers
to 1.
• Keep the default selection of Proximity size function and Curvature size function.
19.8. Generate a Mesh

• Generate a mesh with the modifications using the same settings as before.
Multi-Level Meshing
• Observe the decrease in the number of mesh elements in the Mesh control panel.
• Display a cut plane of the mesh to examine the multi-level meshing around the fan guide.
Figure 19.3: Meshing Levels of the Fan Guide Objects (p. 417) shows a cut plane of the mesh through
the fan guide. Observe the various levels of meshing starting from level 0 and refining to level 2 near
the object interfaces.
Generate a Mesh
Figure 19.3: Meshing Levels of the Fan Guide Objects
• Display the mesh of the plate object guide_sweep-0_1.1 and the block object SheetMetal_HS.
Figure 19.4: Surface Mesh of guide_sweep-0_1.1 (p. 418) shows the surface mesh on the flow guide
for the plate object guide_sweep-0_1.1. Fine mesh resolution in some regions is necessary for
a body fitted mesh. This can be clearly seen in the figure.
Figure 19.5: Surface Mesh of SheetMetal_HS (p. 419) shows the mesh on and around the sheet metal
heatsink. It can be seen that the mesh resolution is fine in the fin region and coarser as we move
away from the heatsink.
Multi-Level Meshing
Figure 19.4: Surface Mesh of guide_sweep-0_1.1
Conclusion
Figure 19.5: Surface Mesh of SheetMetal_HS
19.9. Conclusion
Using multi-level meshing, we were able to improve the mesh resolution and instantly transition to
coarser meshes thus reducing the overall mesh count. Hence, this approach significantly reduces run
time while enhancing the accuracy of the simulation.
In addition, we repeat here some of the tips found in this tutorial for your convenience:
• Use multi-level meshing for CAD objects.
– Set the level of each object by right-clicking it in the Model manager window. Manually specified
objects can have more levels than the maximum number of levels specified.
– Select multiple objects that require the same number of levels to set them simultaneously in the
– Specify the max element size in each of the principal directions to achieve the desired resolution.
→ For example, if you require a resolution of 1 mm and are using 2 levels, then your max element
size should be:
Multi-Level Meshing
• Avoid applying multi-level meshing to the entire model by using non-conformal assemblies and then
activating multi-level meshing in their individual Assemblies object edit panel (under the Meshing
tab).
Chapter 20: Characterizing a BGA-package by
Utilizing ECAD Files
20.1. Introduction
In Tutorials Trace Layer Import for Printed Circuit Boards (p. 347) and Joule/Trace Heating (p. 369) you
learned how to import trace layouts for a PCB. In this tutorial, you will learn how to import trace layouts
on a BGA package substrate by using BOOL files.
• Import trace layout of a BGA package substrate in BOOL format.
• Display traces using the Color by trace option.
• Plot temperature contours on the wirebonds.
• Determine junction-to-case resistance for the package.
Note:
20.2. Prerequisites
You should be familiar with the menu structure in Ansys Icepak and should have solved or read the
tutorial Finned Heat Sink (p. 5) of this guide. Many basic steps found in the introductory tutorials will
not be mentioned here.

In this tutorial, you will see how to determine temperature profiles on the wirebonds of a BGA package
and junction-to-case resistance.

Characterizing a BGA-package by Utilizing ECAD Files
3. Specify a name for your project, such as BGA-package, and then click Create.

To build the model, you will change the units, create the PCB, import the traces and resize the cabinet
to its proper size. Then you will create a wall object.
1. Change the default unit of length to millimeter.
Edit Preferences
a. In the Preferences panel, click Units, under the Defaults node. In the Category box, scroll down
and select Length, and under Units, select mm.
b. Click Set as default, Set all to defaults, and then This project.
2. Create the package object.
a. Click the packages object button ( ) in the objects toolbar.
b. In the Packages panel, click the Dimensions tab and select ASCII Neutral BOOL+INFO from
the Import ECAD file drop-down list.
Figure 20.1: The Packages Panel (Dimensions Tab)
c. Select block_1.bool in the Bool file panel and click Open.
Note:
block_1.bool can be found on the Ansys Help Site. The procedure to download
the file is described below.
2. Download the bga_package.zip file here.
3. Unzip the bga_package.zip file you have downloaded to your working dir-
ectory.
d. Keep the settings for the layers and vias as they are and click Update and Done in the Board
layer and via information panel.
e. Click the Die/Mold tab and assign a die Power of 0.5 W.
f. Click Done.
Note:
If the Objects outside panel is displayed, click the Resize Cabinet button.
g. Click the Cabinet in the object tree and click the Autoscale button located in the edit window
in the lower right corner of the main menu.
Note:
Click the Scale to fit icon ( ) to refocus your model.
h. If the graphics window does not already display the traces by color, right-click the package object
in the object tree, choose Traces Color by trace to display the traces.
Figure 20.2: Display of Traces
As can be seen in Figure 20.2: Display of Traces (p. 425), the wirebonds are lumped into polygonal
plates by Ansys Icepak.
i. Change the cabinet zS to -1.2 mm. If the Objects outside panel appears, click Move so that
the package is fully inside the cabinet.
j. Create a PCB object and input the following in the Geometry tab:
Plane X-Y Specify by Start / end

xS -7.03 mm xE 7.03 mm
yS -7.03 mm yE 7.03 mm
zS -1.2 mm zE —
Note:
If the Objects outside panel appears again, select Allow out to ignore the error. You
will fix the cabinet size later.
k. In the Properties tab, set the substrate thickness as 0.8 mm and then enter the following percent
coverage of copper for the layers:
Figure 20.3: Properties Tab of the Printed Circuit Boards Panel
l. Click Update. Note that Ansys Icepak updates the thermal conductivity information, plane and
normal, for the PCB object.
m. Press Done to close the panel.
n. Create a wall object with zero thickness in the Z direction. Name it Bottom. Enter the same di-
mensions for the wall object as you did for the PCB object created previously as shown in Fig-
ure 20.4: Geometry Window for Object Bottom (p. 427).
Figure 20.4: Geometry Window for Object Bottom
o. Edit the wall object and insulate it by keeping the heat flux as 0.0 in the Properties tab.
p. Make a copy of the wall and translate it in the Z direction by 2.95 mm and rename the new
wall to Top.
• Select the object Cabinet in the Model manager window and then click Autoscale in the
geometry window so that all of the other objects are inside the cabinet.
We would like to specify the heat transfer coefficient on the top surface using the well-known
correlation in the literature, (Incropera et. al [1]). In order to do that, you can follow the procedure
in Figure 20.5: Specifying the Heat Transfer Coefficient on the Top Wall (p. 428).
[1] Frank Incropera and David DeWitt, Fundamentals of Heat and Mass Transfer, John Wiley &
Sons, Inc., New York, 1981.
Figure 20.5: Specifying the Heat Transfer Coefficient on the Top Wall
1. Click the Generate mesh button ( ).
2. In the Mesh control panel (Figure 20.6: Mesh control Panel (p. 429)), enter 0.5 mm, 0.5 mm, and
0.14 mm for the Max element size for X, Y, and Z, respectively. Change the Minimum gap values
to 0.05 mm, 0.05 mm, and 0.01 mm for X, Y, and Z, respectively. In the Misc tab, deselect Allow
minimum gap changes.
Note:
Ensure that Mesh type is Mesher-HD.
3. Click Generate and click Change value and mesh in the Minimum separation panels that appear.
4. Click Close to close the panel once you have created the mesh.
Note:
manager window. See Physical and Numerical Settings of the Finned Heat Sink tutorial for
more instruction regarding the Problem setup wizard. You must still use the same settings
described in this tutorial for the Problem setup wizard.
a. Deselect Flow (velocity/pressure) in the General setup tab.
b. Select Off in the Radiation group box and then click Accept to close the panel.
Note:
Neglecting flow and radiation means that this is a pure conduction problem.
a. Change the Number of iterations to 25 and the Convergence criteria for Energy to 1e-15.
Note:
The absence of flow equations means the problem requires very few iterations to
converge. Since Ansys Icepak is only solving for the energy equation, you require a
very stringent convergence criterion for the energy residual.
i. Choose F from the Type drop-down list.
Note:
These settings aid in convergence when Ansys Icepak solves only the energy equation.
b. In the Precision drop-down list, select Double.
c. Click Accept to save your settings and close the panel.

File Save project

Go to Solve Run solution. Click Start solution.

1. When the model converges, plot the temperatures contours on the wirebond and view the vari-
ation/symmetry of the temperature profiles.
a. Go to Post Object face (node) and choose the wirebonds under the package object.
Figure 20.7: Object face Panel
b. Select Show contours and click Parameters.
c. Select This object from the Calculated drop-down list.
d. Click Done in the Object face contours and Object face panels to close the panels and view
the temperature contours.
Figure 20.8: Temperature Contours on the Wirebonds (Top View)
2. Go to the Report Summary report and click New twice.
a. Choose source_DIE1 under the node for package.1 for the first object and the wall object Top
for the second object.
b. Keep the default selection of Temperature under Value for both.
c. Click Write to create the Summary report.
Maximum die and maximum top wall temperatures are determined to be 131.04°C and 127.6°C, re-
spectively. Note that these values may differ depending on your machine. The top wall represents
the case for the package. Therefore, junction-to-case resistance for this package is determined as:
(20.1)
Where is the die power (0.5 W in this case). Substituting these values, we can calculate the junction-
to-case resistance like so:
(20.2)

In this tutorial, you learned how to import trace layers from a BOOL file onto a BGA package substrate.
You then used this package in conjunction with a PCB and two walls to solve a conduction heat transfer
problem as well as to determine the junction-to-case resistance for the package.
Chapter 21: Zero Slack with Non-Conformal Meshing
21.1. Introduction
This tutorial compares the mesh of a non-conformal assembly with and without slack values around a
heat sink, package, and board. You will solve a model using zero slack values to determine the temper-
ature distribution.
In this tutorial you will learn how to use zero slack values properly with a non-conformal mesh in Ansys
Icepak.
Note:
21.2. Prerequisites
This tutorial assumes that you have reviewed Sample Session and the tutorials Finned Heat Sink (p. 5)
and RF Amplifier (p. 51) of this guide.

The model consists of a detailed heat sink, a BGA package, a block with traces, and fluid blocks. The
model setup is shown in Figure 21.1: Problem Schematic (p. 436).
Zero Slack with Non-Conformal Meshing
Figure 21.1: Problem Schematic
The objective of this exercise is to illustrate the advantage of using zero slack values for non-conformal
assemblies. The model will be constructed using the default metric unit system.

Step 4: Import Traces
2. Download the zeroslack.zip file here.
3. Unzip the zeroslack.zip file you have downloaded to your working directory.
4. Copy the file ZeroSlack_Tut.tzr to your working directory.
The File selection panel appears.
7. In the File selection panel, select the packed project file ZeroSlack_Tut.tzr and click Open.
The Location for the unpacked project file selection dialog appears.
like to place the unpacked project file, enter a project name, such as zeroslack, in the New
project text field, and then click Unpack.
21.5. Step 2: Default Units

Make sure the default unit of length is mm.
Edit Preferences
1. In the Preferences panel, click Units under the Defaults node. In the Category box, scroll down
and select Length, and under Units, make sure mm has an asterisk next to it. If there is no asterisk
next to mm:
a. Select mm from the Units box.
b. Click Set as default.
2. Click Set all to defaults and click This project.

This tutorial uses an existing model. The model contains existing package, board, and heatsink assemblies.
21.7. Step 4: Import Traces

1. In the Model manager window, expand the Board assembly to display the object pcb if it is not
already visible. Right-click pcb in the Model manager window and click Edit to display the Blocks
panel.
2. In the Geometry tab, select ASCII Neutral BOOL+INFO from the Import ECAD file drop-down list.
Important:
You may need to unzip BOARD_OUTLINE_1.zip or extract the BOOL file within it before
you can import the BOOL into Ansys Icepak.
3. In the Bool file panel, select BOARD_OUTLINE.bool. Deselect the Reposition and Resize object
options because the PCB was imported using an IDF file, so the dimensions and location are already
correct. This process may take a few minutes depending on the speed of your computer.
Note:
The Reposition and Resize object options are necessary when the board size and location
are not known or an IDF file is not available.
4. Once the import is complete, you can edit the layer information in the Board layer and via inform-
ation panel. Enter the layer thicknesses as shown in the table below.

1 M1 TOP 0.04
2 D2 DIELECTRIC_U3 0.45364
3 M2 int1 0.062
5 M3 INT2 0.055
7 M4 BOTTOM 0.045
5. By default, layers are lumped for each sub-grid. Therefore, the Model layers separately option is
disabled and will need to be selected.
a. Click Update and Done to close the Board layer and via information panel.
b. Then click Edit next to Trace layers and vias in the Blocks panel to re-open the Board layer
and via information panel.
c. The Model layers separately option is now available. Select the option.
6. The via information is imported automatically, so keep the default settings.
Step 5: Add Slack Values
7. Click Update and Done to save your settings.
Note:
• You can view the traces in four different ways: Single color, Color by trace, Color by
layer, or Color by net.
• The meshing plates are placed at the location of the different layers; they are used to
ensure the mesh resolution is high enough at each layer.
8. Click Done to close the Blocks panel.
21.8. Step 5: Add Slack Values

You will add slack values to the assembly Heatsink.
Note:
Non-conformal assemblies reduce mesh bleeding and lower the overall mesh count. This is
particularly useful for regions where a coarser mesh is sufficient.
1. In the Assemblies panel Meshing tab, click Copy global.
2. Enter 0.05 for Minimum gap Y and 0.1 for Minimum gap Z.
3. Set the slack values for the heat sink assembly as shown in the figure below.
21.9. Step 6: Generate Mesh (with Slack Values)

Generate a mesh for the assembly Heatsink with slack values.
2. Select Mesher-HD as the Mesh type if not already selected.
Step 7: Zero Slack
3. Make sure that the Min elements in gap is 2, the Min elements on edge is 1, and the Max size
ratio is 3.
4. Verify the local meshing parameters.
a. Go to the Local tab and click Edit next to Object params. You will see the following reques-
ted values in the Per-object meshing parameters panel (scroll down to see the inside ratios):
Table 21.1: Object Parameters
Object type Object name Parameter Requested

block pcb X count 25
Z count 5
assembly Heatsink all inside ratios 2
assembly Board all inside ratios 2
assembly Package all inside ratios 2
b. Click Done to close the Per-object meshing parameters panel.
5. Keep all other settings as default and click Generate.
6. Take note of the mesh count and view a cut plane of the mesh from the Display tab.
Note:
The package is not well resolved and it is divided between the heatsink and board assem-
blies. Moreover, the mesh bleeds into the package’s edges significantly because of the
nonzero slack values of the Heatsink assembly on the Min Z and Max Z faces. This prevents
you from creating a separately meshed assembly for the package because non-conformal
assemblies cannot intersect with each other in Ansys Icepak. You can verify this by
changing the view to the positive X orientation.
21.10. Step 7: Zero Slack

Next, we will consider a board with non-conformal meshing with zero slack values.
Non-conformal assemblies with zero slack help in resolving specific objects without extending the mesh
to the rest of the cabinet. Also, zero slack non-conformal assemblies help to avoid intersections with
other non-conformal assemblies. In this tutorial, the use of zero slack non-conformal assemblies allows
us to have a separate non-conformal assembly for the package and to accurately resolve the mesh.
Note:
Currently, zero slack assemblies are unable to participate in radiation when a surface coincides
with the assembly interface.
1. Change the slack values for the heat sink assembly as shown in the figure below.
2. In addition, select the Mesh separately option in the assemblies Package and Board. Do not change
any other values in these assemblies. These other assemblies will have default slack values of zero.
Figure 21.2: Package and Heatsink Assemblies (p. 443) shows the Package and Heatsink assemblies
adjacent to each other without intersection due to the zero slack values in the Z direction for both
assemblies.
Figure 21.2: Package and Heatsink Assemblies
21.11. Step 8: Generate Mesh (with Zero Slack)

Generate a mesh with the same global mesh settings as in Step 6: Generate Mesh (with Slack Val-
ues) (p. 440) so that you can compare the mesh count. Observe that the mesh count is significantly less
than that of the mesh with slack values.

1. In the Model manager window, go to Solution settings Basic settings and Solution
settings Advanced settings, and verify that the following values are set:
Basic settings Value

Energy (convergence 1e-
criterion) 7
Advanced settings
Under-relaxation: Pressure 0.7
Under-relaxation: Momentum 0.3
2. Note:
Model manager window. See 2.7. Step 4: Physical and Numerical Settings (p. 28) of the
Go to Problem setup Basic parameters and make sure the Flow regime is Turbulent
and the turbulence model is Zero equation in the General setup tab. Also, input a small initial
(global) X velocity of –1.5 m/s in Transient setup tab. Click Accept to accept the changes made
and exit the Basic parameters panel.

File Save project

Go to Solve Run solution. Click Start solution.

After the solution has converged, create the following post-processing objects:

cut.1 (plane cut) Set position: Y plane through Plane cut (X-Z) view of the
center velocity vectors in the X-Z plane.
Show vectors
face.1 (object face) Object: pcb Object-face view of temperature
on pcb.
Show contours / Parameters Note the minimum and maximum
Calculated: This object temperatures as well as the
temperature distribution.
Step 13: Summary

face.2 (object face) Object: pcb Object-face showing the thermal
Show contours / Parameters conductivity in the X direction,
K_X.
Contours of : K_X

The zero slack feature in Ansys Icepak alleviates some restrictions encountered when using non-con-
formal assemblies. Zero slack non-conformal assemblies not only reduce mesh count but also allow the
user to mesh specific objects separately. In this model, the zero slack capability allowed you to mesh
the package object separately.
Nonetheless, there are certain limitations of zero slack non-conformal assemblies that you must keep
in mind:
• Surfaces of objects that are coplanar with a zero slack non-conformal interface cannot participate in
radiation.
• Zero slack assembly interfaces cannot touch 2D objects, such as fans, openings, grilles, conducting
thin plates, and so on.
• Zero slack assembly interfaces cannot touch the sides of blocks with individual side specifications.
Always check that objects coplanar with a zero slack interface are correctly meshed.
Chapter 22: Ansys Icepak - Ansys Workbench
Integration Tutorial
22.1. Introduction
This tutorial demonstrates how to create and solve an Ansys Icepak analysis in Ansys Workbench. You
will model a geometry using both Ansys DesignModeler and Icepak. You will then create a non-conformal
mesh for the complex shapes. The project will also include postprocessing the results in Ansys CFD-Post
and performing a static structural analysis in Ansys Mechanical.
• Manage a project using Ansys Workbench
• Import and modify CAD geometry in Ansys DesignModeler
• Create an Ansys Icepak analysis through Ansys Workbench
• Postprocess results in Ansys CFD-Post
• Perform a thermo-mechanical analysis in Ansys Mechanical
Note:
22.2. Prerequisites
This tutorial assumes that you have little experience with Ansys Workbench and so each step will be
explicitly described.

The graphics board contains a heat sink with extruded fins having airfoil cross section, a PCB, capacitors,
memory cards and ports. These objects are placed in a setup as shown in the figure below.
Ansys Icepak - Ansys Workbench Integration Tutorial
Figure 22.1: Problem Schematic

Note:

2. Download the workbench.zip file here.
3. Unzip the workbench.zip file you have downloaded to your working directory.
4. Add a Geometry template by dragging the template from the Toolbar under the Component
Systems node into the Project Schematic. Right-click the Geometry cell (A2) and go to Import
Geometry. Click Browse and select graphics_card_simple.stp to load the geometry.
Note:
A green check mark in the Geometry cell indicates you have imported the geometry
successfully.
5. Right-click the Geometry cell (A2) and select Edit Geometry in DesignModeler as you need to
edit the geometry first before exporting into Ansys Icepak.
a. Go to the Units menu and then select Meter as the desired length unit.
b. Click Generate to display the model.
c. Edit the geometry in DesignModeler using the Electronics option in the Tools menu. Select
Simplify and choose the appropriate simplification level and select bodies.
1. Select All bodies for Selection Filter.
2. Keep the Simplification Type as Level 2. Your settings should resemble those in
Figure 22.2: Details of Simplify1 (p. 450).
Figure 22.2: Details of Simplify1
3. Click Generate.
Refer to the DesignModeler documentation for more detailed information on using

the Electronics options.
Note:
The Electronics menu is shown only if the DesignModeler option Enable

Electronics Options is selected.
d. Close DesignModeler and return to Ansys Workbench.
6. Drag and drop an Icepak template into the Project Schematic on top of the Geometry cell (A2)
to transfer the geometry into Ansys Icepak.
7. Right-click the Setup cell (B2) and select Edit to launch Ansys Icepak.
1. The CAD model appears in the graphics display window and has been converted into Ansys
Icepak objects. Click the isometric toolbar icon ( ) to display the isometric view of the
model.
2. Rename the objects in the edit panel of each of the objects by going to the Info tab then
changing the Name field. Enter the specifications in Properties tab. Table 22.1: Object
Properties (p. 451) shows these specifications.
Note:
You can rename the objects in the edit panel of each of the objects by
going to the Info tab then changing the Name field. To open the object
edit panel, right-click the object and select Edit. After editing the object,
you can press Update to save any changes and click a different object in
the Model manager window to go to that object without closing the
panel.
Table 22.1: Object Properties
Object New name Solid material Total power (W)

SERIAL_PORT no change no change needed no change needed
needed
MEMORY1 MEMORY_1 Ceramic_material 5
MEMORY1.1 MEMORY_2 Ceramic_material 5
CAPACITOR CAPACITOR_1 no change needed no change needed
CAPACITOR.1 CAPACITOR_2 no change needed no change needed
KB no change no change needed no change needed
needed
HEAT_SINK no change no change needed no change needed
needed
CPU no change Ceramic_material 20
needed
ALHPA_MAIN_PCB PCB Create material - PCB sol- no change needed
id_material
Conductivity type:
Orthotropic
X = 20, Y = 0.4, Z =
20
Note:
Edit the Solid material by selecting a material in the drop down list. To
create a Custom material, select Create material in the drop-down list and
click the Properties tab in the Materials panel. Enter the specifications
above.
3. Resize the cabinet in the Cabinet object edit panel.
Model → Cabinet
a. In the Cabinet panel, click the Geometry tab. Under Location, enter the following
coordinates:
Table 22.2: Coordinates for the Cabinet (Specify by: Start / end)
xS = -0.19 m xE = 0.03 m
yS = 0 m yE = 0.028487 m
zS = -0.11 m zE = 0 m
b. Edit the cabinet properties to specify Min x and Max x sides as openings.
i. In the Properties tab of the Cabinet object panel, select Opening from the
drop-down list under Wall type for Min x and Max x.
ii. Select Edit to display the opening for the Max x object panel.
iii. In the Properties tab, specify the X Velocity to be -2 m/s. Click Done in the
Openings and Cabinet panels to apply the changes and close the panels.
4. The final model should correspond to the one shown below.
Figure 22.3: The Final Model Display
1. Click the assembly toolbar icon ( ) to create an assembly. Add the HEAT_SINK and CPU objects
to the assembly and rename it CPU_assembly.
Note:
To add objects to an assembly, select one or more objects in the Model manager window
and drag them into the desired assembly node.
2. Go to the CPU_assembly edit panel and click the Meshing tab. Select the Mesh separately option
and enter the following slack values. Click Done to close the panel when finished.
Table 22.3: Slack Values
Min X = 0.005 m Max X = 0.005 m

Min Y = 0.0016 m Max Y = 0 m
Min Z = 0.001 m Max Z = 0.005 m
3. Specify the overall mesh controls as shown in the Mesh control panel below.
Model → Generate mesh
Note:
For more information on how to refine a mesh locally, refer to Refining the Mesh Locally
in the Icepak User’s Guide.
Note:
The Mesh units and Minimum gap values are in mm, and Set uniform mesh params
is selected in the Global tab.
Click Generate to create the mesh. You can check the mesh by going to the Display and Quality
tabs in the Mesh control panel. Click Close when you are done.
Note:
manager window. See Step 4: Physical and Numerical Settings (p. 28) of the Finned Heat
1. Go to Problem setup → Basic parameters in the Model manager window.
a. In the General setup tab, make sure that both Flow (velocity/pressure) and Temperature are
selected.
b. Select Turbulent and Zero equation for the Flow regime and select Off in the Radiation group
box to neglect radiation modeling.
c. Click Accept to close the panel.
2. Go to Solution settings → Basic settings and Solution settings → Advanced settings

in the Model manager window and verify that the following values are set for each variable:
Basic settings User input

Flow (convergence criterion) 0.001
Energy (convergence criterion) 1e-7
Advanced settings (Under-relaxation)
Pressure 0.3
Momentum 0.7

1. Go to File → Save project.
Note:
You can click the save icon ( ) in the File commands toolbar.
The Save As panel appears.
2. Specify the name ice_wb for your project and click Save.

1. Go to Solve → Run solution to display the Solve panel.
2. Keep the default settings in the Solve panel.
Ansys Icepak begins to calculate a solution for the model and a separate window opens where the
Note that the actual values of the residuals may differ slightly on different machines, so your plot
may not look exactly the same as the figure below.
4. Once the solution converges, click Done in the Solution residuals window to close it.
Step 7: Examine the Results with CFD-Post
22.10. Step 7: Examine the Results with CFD-Post
Note:
The postprocessing of results can be done within Ansys Icepak; however, you can also examine
results in Ansys CFD-Post. This section will describe how to transfer information to Ansys
CFD-Post and use its postprocessing options, so you may close Ansys Icepak.
1. After calculating a solution in Ansys Icepak, a green check mark will be displayed in the Icepak
Solution cell in the Project Schematic. The green check mark indicates that all data is up to date.
Select Results under the Component Systems node in the Toolbox. Drag the Results component
system on top of the Icepak Solution cell (B3) to transfer the data.
2. Double-click the C2 Results cell to launch Ansys CFD-Post. The model should appear in the display
window.
3. To generate contours, do the following:
a. Go to Insert → Contour or click the Contour button to create a contour. Retain the name
Contour 1 and click OK.
b. In the Geometry tab under Details of Contour 1:
i. Keep the default selection of All Domains in the Domains drop-down list.
ii. Click the ... button next to Locations to display the Location Selector panel. Highlight
all objects containing "CPU", "PCB", or "HEAT_SINK" in the name as shown in Fig-
ure 22.4: Location Selector Panel (p. 460). Click OK to close the panel.
Figure 22.4: Location Selector Panel
Note:
You can select multiple objects by pressing and holding either Shift or Ctrl
while clicking the objects.
Step 7: Examine the Results with CFD-Post
iii. Select Temperature in the Variable drop-down list.
iv. Select Apply to display the contour map (Figure 22.5: Contour 1 (p. 461)).
Note:
Ensure that the units are set to Celsius.
Figure 22.5: Contour 1
4. To generate a 3D streamline, do the following:
a. Go to Insert → Streamline or click the Streamline button to create the streamline. Retain
the name Streamline 1 and then click OK.
b. In the Geometry tab under Details of Streamline 1:
i. Keep the default selection of 3D Streamline in the Type drop-down list.
ii. Keep the default selection of All Domains in the Domains drop-down list.
iii. Select cabinet_default_side_maxx minx from the Start From drop-down list.
iv. Keep the default selection of Velocity in the Variable drop-down list.
v. Keep all other defaults and click Apply to display the streamline.
c. You can also animate the streamline. To animate the streamline, go to Tools → Animation or
click the animation button .
• In the Animation panel that appears, select Streamline 1 and then click the play button
( ). Click the stop button ( ) then the Close button when finished.
5. When you are done examining the results, close Ansys CFD-Post and return to Ansys Workbench.
22.11. Step 8: Thermo-Mechanical Structural Analysis

In addition to solving this problem in Ansys Icepak, you can also perform a static structural analysis
using Ansys Mechanical.
1. Select Static Structural from the Toolbox. Drag and drop this cell on top of the Icepak Solution
cell (B3).
2. Click the Geometry cell (A2) and drag and drop it on top of the Static Structural Geometry cell
(D3). You have now shared the geometry with the Static Structural component module as well as
the Icepak module from earlier.
3. Right-click the Setup cell (D5) and then click Update. Allow Ansys Workbench to complete the update.
Step 9: Summary
4. Double-click the Model cell (D4) to launch Ansys Mechanical.
5. Expand the Imported Load (Solution) node in the Outline window then click the Imported Body
Temperature object.
6. Under Details of “Imported Body Temperature”, ensure that the Scoping Method is Geometry
Selection.
a. Click the Box Select button . Hold down the Ctrl key and drag a box
around the entire model to select it.
b. Click the cell to the right of Geometry and then click Apply. You should have nine bodies
now selected.
7. Select All from the Icepak Body drop-down list.
8. Click Solve.

In this tutorial, you used Ansys Workbench to manage a multi-stage project using Ansys DesignModeler,
Icepak, CFD-Post, and Mechanical. In particular, you used DesignModeler to import and modify CAD
objects then shared the geometry with Ansys Icepak. You then used Ansys Icepak to determine temper-
ature and flow results within the system. In CFD-Post, you post-processed the solution results from
Ansys Icepak. Finally, you used Mechanical to perform a structural analysis of the system using the
temperature data from Ansys Icepak. Ansys Workbench allows you to integrate these software for more
control over the various aspects of your project.
Chapter 23: Postprocessing Using Ansys CFD-Post
23.1. Introduction
This tutorial demonstrates the use of Ansys CFD-Post for post-processing results from Ansys Icepak
analyses.
• Create a workflow in Ansys Workbench.
• Postprocess Ansys Icepak results in Ansys CFD-Post.
Note:
23.2. Prerequisites
• Familiarity with the Ansys Workbench interface
• Familiarity with the Ansys Icepak interface
Postprocessing Using Ansys CFD-Post
Figure 23.1: Quick Reference - CFD Post Interface
Figure 23.2: Quick Reference - Mouse Button Mapping (default) in CFD Post:
To adjust or view the mouse mapping options, go to Edit Options, then Viewer Setup Mouse
Mapping in Ansys CFD-Post.
Step 1: Create a New Project

Figure 23.3: Problem Schematic - Graphics Card Model (two configurations) (p. 467) shows the Ansys
Icepak model of a graphics card that contains a printed circuit board. The board components include
memory cards, capacitors, CPU, and serial connectors for peripheral devices. The CPU is cooled by a
heat sink. A fan and grille have been used to enhance the convective heat transfer within the system.
Two configurations, varying the positioning of the fan and grille, will be considered for CFD analysis.
Figure 23.3: Problem Schematic - Graphics Card Model (two configurations)

1. Create a workflow by linking Ansys Icepak and Ansys CFD-Post in Ansys Workbench.
a. Start a new Ansys Workbench session.
b. Drag an Ansys Icepak component module from the Toolbox and drop it on the Project
Schematic window as shown in Figure 23.4: Creating an Ansys Icepak Component (p. 468).
Figure 23.4: Creating an Ansys Icepak Component
c. Rename the Ansys Icepak component module as Parametric Setup as shown in Figure 23.5: Re-
naming the Ansys Icepak Component Module (p. 468). To rename the title, double-click the title
Icepak or click the down arrow ( ) and select the Rename option from the drop-down list.
Figure 23.5: Renaming the Ansys Icepak Component Module
d. As shown in Figure 23.6: Linking the Results (Ansys CFD-Post) Component to the Ansys Icepak
Component (p. 469) and Figure 23.7: Final Project Schematic (p. 469), drag and drop a Results
(Ansys CFD-Post) component module onto the Solution cell of the Parametric Setup to link
the Ansys Icepak analysis to Ansys CFD-Post. Rename the Results component module to CFD
Post.
Figure 23.6: Linking the Results (Ansys CFD-Post) Component to the Ansys Icepak Component
Figure 23.7: Final Project Schematic
e. Save the project while in the Ansys Workbench interface. Name the project as ice-cfdpost.
2. Download the project file.
1. Download the cfd_post.zip file here.
2. Unzip the cfd_post.zip file you have downloaded to your working directory.
3. Copy the file ice-cfdpost.tzr to your working directory.
3. Open the project in Ansys Icepak
a. Right-click the Ansys Icepak Setup cell and import the packed Ansys Icepak project file ice-
cfdpost.tzr located in the project directory.
b. The Ansys Icepak interface will launch with the imported project for modeling and analysis.
23.5. Step 2: Parametric Trials and Solver Settings

1. Go to Edit Preferences Postprocessing and confirm that the Merge zones when possible
for CFD-Post data option is selected.
2. Go to Solve Run solution Results and verify that Create heat flux vectors in CFD Post is
selected and then click Dismiss.
3. Go to Solve Run optimization.
a. In the Design variables tab, review the parametric setup. Note the variable values for fanxC
and grille_xS.
b. In the Trials tab, note that two of the four trials will be considered for CFD analysis.
Figure 23.8: Solution Trials

1. Click Run in the Parameters and optimization panel.
2. Ansys Icepak will run two trials and automatically write out the results for post-processing in Ansys
CFD-Post at the end of each trial.
3. Save the project by going to File Save project.
4. Close Ansys Icepak by going to File Close Icepak.
23.7. Step 4: Postprocessing Using Ansys CFD-Post

1. Open the results in Ansys CFD-Post.
a. On the project schematic, double-click the Results cell (B2) to launch the Ansys CFD-Post interface.
b. Ansys CFD-Post automatically reads the most recent solution set (trial 004).
2. Create a Surface Group for the board and all the components.
a. Go to Insert Location Surface Group.
b. Name the group as BoardANDComponents.
c. Go to the Details view located on the lower left hand side of the screen (see Figure 23.1: Quick
Reference - CFD Post Interface (p. 466)).
Figure 23.9: Details View for BoardANDComponents Surface Group
d. In the Geometry tab, click next to Locations to open the Location Selector panel.
i. As shown in Figure 23.10: Selection for the BoardANDComponents Surface Group (p. 473),
hold down Shift and the left mouse button to select all of the objects excluding the objects
in the Cabinet node. You may need to press the Ctrl key also to select the objects.
Step 4: Postprocessing Using Ansys CFD-Post
Figure 23.10: Selection for the BoardANDComponents Surface Group
ii. Click OK to close the Location Selector panel and add the surfaces.
e. Click Apply in the Details view to apply the settings.
3. Create another Surface Group for the cabinet.
a. Go to Insert Location Surface Group and name the group CabinetSurfaces. Click
Apply in the Details view. CabinetSurfaces should now appear in the Outline tree view.
Figure 23.11: Listing of Surface Groups under User Locations and Plots
b. As before, open the Location Selector panel, but this time select only the objects in the Cabinet
node (Figure 23.12: Selection for the CabinetSurfaces Surface Group (p. 474)). Click OK.
Figure 23.12: Selection for the CabinetSurfaces Surface Group
c. In the Render tab, apply the settings as shown in Figure 23.13: Rendering Details for the Cabin-
etSurfaces Surface Group (p. 475) and click Apply.
Figure 23.13: Rendering Details for the CabinetSurfaces Surface Group
d. Deselect the object BoardANDComponents from the User Locations and Plots node in the
Outline tree view.
Figure 23.14: Updated Model
e. Note that these newly created Surface Groups are listed under User Locations and Plots in the
Outline tree view.
4. Plot Contours of Temperature on the Surface Group BoardANDComponents.
a. Change the Units for this postprocessing session.
i. Go to Edit Options Units.
ii. Set the System to Custom.
iii. Ensure that the unit for Temperature has been set to C.
Figure 23.15: Setting Units in CFD Post
iv. Click Apply and then OK to set the units and close the panel.
b. Go to Insert Contour and create a new contour object named TemperatureContours.
c. For the contour TemperatureContours, update the settings for the Geometry tab of the
Details view as shown in Figure 23.16: Geometry Settings for TemperatureContours (p. 478) and
click Apply.
Figure 23.16: Geometry Settings for TemperatureContours
d. Click Apply to create the contour.
Note:
The object TemperatureContours is listed under the User Locations and Plots
node in the Outline tree view.
5. Modify the display of the default legend view.
a. Double-click Default Legend View 1 listed under the User Locations and Plots node (in the
Outline) to access the corresponding Details view.
b. Verify that your settings in the Definitions and the Appearance tabs match those shown in
Figure 23.17: Settings for Default Legend View 1 (p. 479) and then click Apply.
Figure 23.17: Settings for Default Legend View 1
Figure 23.18: Modified Legend View
6. Plot Vectors, displaying heat flux on the Surface Group BoardANDComponents.
a. Deselect TemperatureContours in the User Locations and Plots node.
b. Go to Insert Vector and create a new Vector object named HeatFluxVectors and click
OK.
c. Modify the Geometry tab of the Details view as shown in Figure 23.19: Geometry Settings for
HeatFluxVectors (p. 480).
Figure 23.19: Geometry Settings for HeatFluxVectors
d. Go to the Symbol tab and input 2.5 for the Symbol Size. Click Apply and then observe the
updated model.
Figure 23.20: Display of HeatFluxVectors
7. Plot Thermal Chokepoint, displaying regions of high heat flux on the Surface Group BoardAND-
Components.
a. Deselect HeatFluxVectors in the User Locations and Plots node.
b. Go to Insert Contour and create a new Contour object named Chokepoint and click OK.
c. Open the Location Selector panel and select only the ALPHA_MAIN_PCB objects (Figure 23.21: Se-
lection for Thermal Chokepoint (p. 482)). Click OK to close the Location Selector panel and add
the surfaces.
Figure 23.21: Selection for Thermal Chokepoint
d. Modify the Geometry tab of the Details view as shown in Figure 23.22: Geometry Settings for
Chokepoint (p. 483) and click Apply.
Figure 23.22: Geometry Settings for Chokepoint
Figure 23.23: Display of Chokepoint
8. Plot Streamlines originating from the fan and colored by temperature.
a. Deselect Chokepoint and select TemperatureContours in the User Locations and Plots node.
b. Go to Insert Streamline and create a new Streamline object named StreamlinesFan

and click OK to access the Details view panel.
c. Modify the Geometry tab as shown in Figure 23.24: Geometry Settings for StreamlinesFan (p. 485)
and click Apply.
Figure 23.24: Geometry Settings for StreamlinesFan
d. Modify the Color tab as shown in Figure 23.25: Color Settings for StreamlinesFans (p. 485) and
click Apply.
Figure 23.25: Color Settings for StreamlinesFans
e. Modify the Symbol tab as shown in Figure 23.26: Symbol Settings for StreamlinesFan (p. 486) and
click Apply.
Figure 23.26: Symbol Settings for StreamlinesFan
Figure 23.27: Display of StreamlinesFan
9. Create a Keyframe Animation of StreamlinesFan.
a. Go to Tools Animation and select Keyframe Animation.
b. Click the button to insert a new frame called KeyframeNo1 as shown in Figure 23.28: Keyframe
Animation Panel (p. 488).
Figure 23.28: Keyframe Animation Panel
c. Right-click the background next to the model in the 3D viewer and select the View From +Y
option under Predefined Camera.
Figure 23.29: View From +Y
d. Add another keyframe called KeyframeNo2 to the Animation panel.
e. Select the Animate Camera option on the Keyframe Animation panel (you may need to activate
the display of the lower half of the Animation panel using the drop-down arrow ).
f. Similarly, update the display and add new frames as follows:
i. View From -Z and add KeyframeNo3.
ii. View From +X and add KeyframeNo4.
iii. Isometric View (Y up) and add KeyframeNo5.
g. Click to view the animation.
h. Click the Options button on the Animation panel to access the Animation Options panel.
i. Set the Animation Speed to Slower from the drop-down menu by a factor of 20 and click OK.
Figure 23.30: Animation Options Panel
j. Replay the animation and note that the animation is less choppy compared to the original one.
k. Close the Keyframe Animation panel.
l. Deselect the TemperatureContours and StreamlinesFan objects under User Locations

and Plots.
10. Create a Plane object displaying temperature contours and velocity vectors.
a. Go to Insert Location Plane and create a plane named PlaneCut.
b. Modify the Details view for PlaneCut as shown in Figure 23.31: Details for PlaneCut (p. 491)
and click Apply.
Figure 23.31: Details for PlaneCut
c. Deactivate the display of the plane by deselecting PlaneCut and activate the contour display
by selecting TemperatureContours under User Locations and Plots.
d. Double-click TemperatureContours or right-click Edit to access the Details view. Update

the details as shown in Figure 23.32: Details for TemperatureContours (p. 492) and click Apply.
Figure 23.32: Details for TemperatureContours
Figure 23.33: Display of PlaneCut
e. Go to the Details view for the PlaneCut (do not activate the display of the PlaneCut) and
make the following modifications:
i. Switch Method to XY Plane and click Apply.
ii. Use the scroll bar to change the Z location for PlaneCut.
f. The plane cut can also be traversed across the domain using the animation tools in CFD-Post.
i. Go to Tools Animation and select Quick Animation (default) and highlight the PlaneCut
object.
ii. Using the slider bar, adjust the number of frames for the animation (how fast or slow it plays)
as shown in Figure 23.34: Quick Animation Settings (p. 494) and click the button.
Figure 23.34: Quick Animation Settings
iii. The animation can be viewed on the screen or can be written out to an animation file by
checking the Save Movie option.
iv. Stop the animation by clicking the button.
v. Click Close to exit the Animation panel.
g. Deactivate the display of the contours by deselecting the TemperatureContours object under
User Locations and Plots.
h. Go to Insert Vector and create a vector object named VelVectors.
i. Modify the Details view for VelVectors to set the Locations to PlaneCut and click Apply.
j. As before, use the Details view for the PlaneCut to manually traverse the plane displaying
the vectors across the domain.
k. Deactivate the display of the vectors by deselecting Velvectors under User Locations and
Plots.
11. Create an Isosurface of 27°C and 3 m/s.
a. Go to Insert Location Isosurface and create an Isosurface name HotSpots.
b. Modify the Details view for HotSpots to create an isosurface for 27[C] (Variable: Temperature,
Value: 27°C).
c. Similarly, modify the Details to create an isosurface for 3 m/s (Variable: Velocity, Value: 3
m/s).
d. Deactivate the display of the isosurface by deselecting HotSpots under User Locations and
Plots.
12. Create a Volume for values above 25°C.
a. Go to Insert Location Volume and create a Volume named IsoVolume.
b. Modify the Details view for IsoVolume as shown in Figure 23.35: Details of IsoVolume (p. 495)
and click Apply.
Figure 23.35: Details of IsoVolume
Figure 23.36: Display of IsoVolume
c. Deactivate the display of the volume by deselecting IsoVolume under User Locations and
Plots.
13. Create a Chart of Temperature variation across a Line.
a. Go to Insert Location Line and create a Line named ForChart.
b. Modify the Details view for ForChart as shown in Figure 23.37: Details for Line ForChart (p. 496).
and click Apply.
Figure 23.37: Details for Line ForChart
c. Deactivate the display of the line by deselecting ForChart under User Locations and Plots.
d. Go to Insert Chart to create a Chart named TemperatureVariation.
e. Modify the Details for TemperatureVariation as follows:
i. General tab: Set the Type to XY.
ii. General tab: Set the Title to Temperature Variation along Z axis.
iii. Data Series tab: Set Location to ForChart.
iv. X Axis tab: Set Variable to Z.
v. Y Axis tab: Set Variable to Temperature.
f. Leave all other settings as their defaults and click Apply.
Figure 23.38: Plot of TemperatureVariation Along ForChart
Note:
The chart TemperatureVariation is added under the Report node of the Outline
tree.
14. Create an Expression and Variable that can be used for postprocessing.
a. Switch to the Expressions tab (located next to the Outline tab) and review the list of available
expressions.
i. Right-click in the white space and click New to create a new expression named VelocityR-
atio.
ii. Click Ok to access the Details view for VelocityRatio.
iii. Right-click the white space in the Definition tab to access the Functions, Expressions,
Variables, Locations and Constants which will be used to create the expression VelocityR-
atio.
iv. Create the expression as shown in Figure 23.39: Expression for VelocityRatio (p. 499) and click
Apply.
Figure 23.39: Expression for VelocityRatio
Note:
Velocity is found under Variables, volumeAve()@ is found under Functions

CFDPost, and Cabinet is found under Locations Other.
b. Switch to the Variables tab and review the list of Derived, Geometric, Solution, and User
Defined variables.
i. Right-click the white space and click New to create a new variable named VelRatio.
ii. Click Ok to access the details view for VelRatio.
iii. Select Expression for the Method and select VelocityRatio for the Expression.
iv. Click Apply to create VelRatio.
Note:
VelRatio is listed under the User-Defined type of Variables.
c. You can now plot Contours, Isosurfaces, Vectors, Charts, and so on using the new variable
VelRatio.
Step 5: Comparison Study
23.8. Step 5: Comparison Study

1. Open a new Ansys CFD-Post session
a. Go to File Close CFD Post to close the existing Ansys CFD-Post session.
b. In the Ansys Workbench project schematic, right-click the Solution cell of the parametric setup
component to transfer the solution data to a new Results component, as shown in Fig-
ure 23.40: Creation of New Results Component (p. 502).
c. Rename the Results component to Comparison Study.
Figure 23.40: Creation of New Results Component
d. Double-click the Results cell of Comparison Study to launch a new Ansys CFD-Post session.
Note:
As before, Ansys CFD-Post automatically reads in the most recent solution set (trial
004).
2. As shown in Figure 23.41: The Load Results Panel (p. 503), go to File Load Results to load an
additional solution set. Navigate to the ~ice-cfdpost_files/dp0/IPK/Icepak/IcepakProj
folder to pick trial001.cfd.dat as the second solution set for the comparison study.
Note:
The root directory ~ice-cfdpost_files refers to the project folder in which you
have saved the Ansys Workbench project for this tutorial.
Figure 23.41: The Load Results Panel
3. Set up the display of the two solution sets.
a. Synchronize the camera and the visibility in the displayed views by selecting the corresponding
buttons from the Shortcuts Toolbar located directly above the models in the 3D viewer displays.
b. Rotate, Zoom, or Pan one of the displays and confirm that the other display follows suit.
c. Using the Shortcuts Toolbar, modify the display to a landscape view (switch from to )
4. As before, go to Insert Location Surface Group and create a Surface Group named
BoardAndComponents.
Important:
The Surface Group in this Ansys CFD-Post session should include the board and compon-
ent surfaces from both solution sets. Use the Location Selector to select all the objects
excluding the cabinet objects for each list. The easiest way to do this is to select all the
objects from both groups using Shift and the left mouse button, then deselecting the
cabinet objects from both groups using Ctrl and the left mouse button. Click Apply to
create the surface group.
Figure 23.42: Display of BoardAndComponents
5. Deselect BoardAndComponents from User Locations and Plots.
6. As before, go to Insert Contour and create a new contour object named TemperatureCon-
tours and set its Locations to the BoardAndComponents Surface Group. Set Variable to
Temperature and click Apply.
7. Update the display of the Default Legend View (each display will need to be updated individually)
as before.
Figure 23.43: Display of Legend View
8. Go to Insert Streamline and create a Streamline object named StreamlinesFans and edit
the Details as below:
a. Geometry tab: Select fan1_minx from both solution sets for Start From and set # of Points
to 50.
Tip:
Click the button ... next to Start From to select both fan1_minx objects more easily.
b. Color tab: Set Mode to Variable and select Temperature for Variable.
c. Symbol tab: Select Show Symbols and Show Streams. Set the Interval to 0.005 s.
d. Click Apply.
Figure 23.44: Display of Streamlines Comparison
Step 6: Summary
e. Perform a detailed comparison study using the various features (Isosurface, Plane, Animation
etc.) discussed earlier in this tutorial.

In this tutorial, you learned how to import an Ansys Icepak project from a TZR file in Ansys Workbench.
You then learned how to use a solution that was solved in Ansys Icepak and postprocess it in Ansys
CFD-Post using various postprocessing options. You also learned how to compare parametric solutions
side-by-side in Ansys CFD-Post.
Chapter 24: High Density Datacenter Cooling
24.1. Introduction
This tutorial demonstrates how to model a datacenter using Ansys Icepak.
• Use macros to create computer room air conditioning units (CRACs), server cabinets, power distribution
units (PDUs), and perforated floor tiles in the datacenter.
• Organize the model using groups.
• Include effects of gravity and turbulence in the simulation.
• Define object-specific meshing parameters.
• Create contours, particle traces, iso-surfaces to better understand the airflow patterns and temperature
stratification within the datacenter space.
Note:
24.2. Prerequisites
solved or read the tutorial Finned Heat Sink (p. 5) of this guide. Some steps will not be shown explicitly.

This tutorial considers a 1200 sq. ft. datacenter with a slab to slab height of 12 ft as shown in Fig-
ure 24.1: Geometry of the Datacenter Model (p. 510). The datacenter consists of a 1.5 ft underfloor
plenum and a 2 ft ceiling plenum. The CRACs discharge cold air into the underfloor plenum. The cold
air enters the main datacenter space mainly through the perforated floor tiles and returns back to the
air conditioning units as shown in Figure 24.2: Expected Airflow Path (p. 510). The cooling load, as sum-
High Density Datacenter Cooling
marized in Table 24.1: Size and Capacity of Heat Sources in Datacenter (p. 510) corresponds to the heat
output from the server cabinets and the PDUs.
Table 24.1: Size and Capacity of Heat Sources in Datacenter
Heat Size Power

Source
Server 2 ft x 3 ft x 7 3000
Cabinet ft W
High Density 2 ft x 3 ft x 7 7000
ft W
PDU 4 ft x 2 ft x 5 3600
ft W
Figure 24.1: Geometry of the Datacenter Model
Figure 24.2: Expected Airflow Path
Step 2: Set Preferences

3. Specify a name for your project such as datacenter and click Create.
Note:
its default orientation, select Home position in the Orient menu.
24.5. Step 2: Set Preferences

1. Go to Edit Preferences. The Preferences panel opens.
2. Go to Display in the Options node.
a. Select Float for the Color legend data format and enter 2 under Numerical display precision.
3. Go to Editing in the Options node.
a. Set the Default dimensions to Start/length.
4. Go to Object types in the Options node.
a. Turn off Decoration for all object types and update line Width to 2 for blocks, fans, openings,
plates, resistances and grilles.
Figure 24.3: The Preferences Panel - Object types
5. Go to Units in the Defaults node.
a. Click Set all to Imperial.
b. Click This project to apply the preferences to this project.

To build the model, you will first resize the cabinet to its proper size. Then you will create the features
of the datacenter, including CRACs (2), server cabinets (44), perforated floor tiles (44), raised floor (1),
dropped ceiling (1), return grilles (8), PDUs (2), cable trays (4), columns (2) and miscellaneous blockage
(1).
1. Resize the default cabinet.
a. Select the Cabinet in the Model tree and specify the following in the object geometry window:
b. Press Apply to resize the cabinet.
c. Click the Isometric view button ( ) and then the Scale to fit button ( ) to show a scaled-to-
fit isometric view of the cabinet.
Note:
The walls of the cabinet are adiabatic and do not participate in radiation by default.
Radiation will not be considered for this analysis.
2. Create the raised floor.
a. Click the Create plates button ( ).
Ansys Icepak creates a free rectangular plate in the x-y plane in the center of the cabinet. You
need to change the orientation and size of the plate and its location within the cabinet.
b. In the object geometry window:
i. Set the Name to raisedfloor.
ii. Change the Plane to xz.
iii. Enter the following dimensions:
iv. Press Apply to resize and rename the object.
3. Create the first CRAC unit.
a. Go to Macros Geometry Data Center Components CRAC to open the Create CRAC
panel.
b. Enter the dimensions as shown below in Figure 24.4: The Create CRAC Panel (p. 514).
c. Make sure the Flow direction is -Y.
d. Select Mass flow rate and input a value of 15.9 lbm/s.
e. Specify a Supply temperature of 55 F.
Figure 24.4: The Create CRAC Panel
Note:
Mass flow rate has units of lbm/s.
f. Press Accept to create the CRAC unit.
Figure 24.5: The CRAC Unit in the Graphics Window
4. Set the per-object meshing parameters for the fans crac_intake and crac_exhaust.
a. Open the Mesh control panel by clicking the Generate mesh button ( ).
b. In the Local tab, check Object params and press Edit.
i. In the Per-object meshing parameters panel, Ctrl+left click crac_exhaust and

crac_intake to select both objects.
ii. Check the Use per object parameters option.
iii. Check the X count and Z count options and specify a Requested value of 4 for both options.
Figure 24.6: Per-object Meshing Parameters for the Fans
c. Click Done to close the Per-object meshing parameters panel.
d. Click Close to close the Mesh control panel.
5. Create a new group for the CRAC unit.
a. Select all the CRAC objects by Shift+left clicking cracunit and then crac_exhaust in the
b. Right click one of the selected objects and go to Create and then Group.
c. In the Create group panel, enter CRACs in the Name for new group text field.
d. Press Done to create the new group.
6. Create the second CRAC unit.
a. Expand the Groups node in the Model manager window.
b. Right click CRACs and select Copy.
c. In the Copy group panel, check Group name and enter CRACs.
d. Check Translate and set the Z offset to 10 ft.
Figure 24.7: The Copy Group CRACs Panel
e. Press Apply and Done to copy the CRAC unit and close the panel.
Figure 24.8: Two CRAC Units in the Graphics Window
f. Now may be a good time to Save the project ( ).
7. Create a row of server racks.
a. Go to Macros Geometry Data Center Components Rack (Front to Rear).
b. Input the dimensions as show below in Figure 24.9: The Create Rack (Front to Rear) Panel (p. 519).
c. Set the Flow direction to -X.
d. Specify a Heat load of 3000 W.
e. Specify a Volume flow of 450 cfm.
f. Set the Number of racks to 11.
g. Under Create additional racks along select +Z.
Figure 24.9: The Create Rack (Front to Rear) Panel
h. Press Accept to create the server racks.
Figure 24.10: Row of Server Racks in the Graphics Window
Note:
The volumetric flow rate input for the recirculation opening is converted by Ansys
Icepak to a mass flow rate input to the computational stage of the analysis. For this
conversion, Ansys Icepak uses the density specified for Air in the materials panel as
shown below.
8. Create a new group for the server racks.
a. Select all the server rack objects by Shift + left clicking rack and then rack-opns.10 in the
c. In the Create group panel, enter RACKs in the Name for new group text field.
9. Create a second row of server racks.
a. Right click RACKs in the Groups node and select Copy.
b. In the Copy group panel, check Group name and enter RACKs.
c. Check Rotate and Translate in the Operations group box.
d. Set the Axis to Y and the Angle to 180.
e. Set the X offset to 7 ft.
Figure 24.11: The Copy Group RACKs Panel
f. Press Apply and Done to copy the row of server racks and close the panel.
Figure 24.12: Two Rows of Server Racks in the Graphics Window
10. Create a row of high density server racks.
a. Go to Macros Geometry Data Center Components Rack (Front to Rear).
b. Enter hdrack in the Name text field.
c. Input the dimensions as show below in Figure 24.13: The Create Rack (Front to Rear) Panel (p. 524).
d. Set the Flow direction to -X.
e. Specify a Heat load of 7000 W.
f. Specify a Volume flow of 1000 cfm.
g. Set the Number of racks to 11.
h. Under Create additional racks along select +Z.
Figure 24.13: The Create Rack (Front to Rear) Panel
i. Press Accept to create the high density server racks.
11. Create a new group for the high density server racks.
a. Select all the high density server rack objects by Shift+left clicking hdrack and then hdrack-
opns.10 in the Model manager window.
c. In the Create group panel, enter HDRACKs in the Name for new group text field.
12. Create a second row of high density server racks.
a. Right click HDRACKs in the Groups node and select Copy.
b. In the Copy group panel, check Group name and enter HDRACKs.
c. Check Rotate and Translate in the Operations group box.
d. Set the Axis to Y and the Angle to 180.
e. Set the X offset to 7 ft.
f. Press Apply and Done to copy the row of high density server racks and close the panel.
Figure 24.14: Two Rows of High Density Server Racks in the Graphics Window
13. Create a row of perforated tiles.
a. Go to Macros Geometry Data Center Components Tile.
b. Set the Number of tiles to 11.
c. Enter the dimensions as show below in Figure 24.15: The Create Tile Panel (p. 526).
d. Choose +Z.
e. Enter 0.35 for Uniform under % Open area.
Figure 24.15: The Create Tile Panel
f. Press Accept to create the tiles.
Figure 24.16: Row of Tiles in the Graphics Window
14. Set the per-object meshing parameters for all the resistance objects.
b. In the Local tab, press Edit next to the Object params option.
i. In the Per-object meshing parameters panel, Shift+left click tile and then tile.10 to
select all the resistance objects.
iv. Check the Y count option and specify a Requested value of 3.
Figure 24.17: Per-object Meshing Parameters for the Tiles
15. Create a new group for the perforated tiles.
a. Select all the tile objects by Shift+left clicking tile and then tile_open_bottom.10 in the
c. In the Create group panel, enter TILEs in the Name for new group text field.
16. Create three more rows of perforated tiles.
a. Right click TILEs in the Groups node and select Copy.
b. In the Copy group panel, check Group name and enter TILEs.
c. Check Translate and set the X offset to 2 ft.
d. Press Apply and Done to copy the row of perforated tiles and close the panel.
e. Right click TILEs in the Groups node again and select Copy.
f. In the Copy group panel, check Group name and enter TILEs.
g. Check Translate and set the X offset to 14 ft.
h. Press Apply and Done to copy both rows of perforated tiles and close the panel.
Figure 24.18: Four Rows of Tiles in the Graphics Window
17. Create the ceiling plenum.
a. Click the Create plates button ( ).
i. Set the Name to ceilingplenum.
ii. Change the Plane to xz.
18. Create a return grille.
a. Click the Create grille button ( ).
b. Double click the grille.1 object in the Model manager window to open the Grille panel.
c. In the Info tab, enter ceiling-return under Name and enter CEILING-RETURN under
Groups.
d. In the Geometry tab, set the Plane to X-Z and enter the following dimensions:
e. In the Properties tab, set the Free area ratio to 0.5.
f. Press Done to apply the settings and close the panel.
19. Create two rows of return grilles.
a. Right click CEILING-RETURN in the Groups node and select Copy.
b. Set the Number of copies to 2.
c. In the Copy group panel, check Group name and enter CEILING-RETURN.
d. Check Translate and set the Z offset to 9 ft.
e. Press Apply and Done to copy the return grille and close the panel.
f. Right click CEILING-RETURN in the Groups node again and select Copy.
g. In the Copy group panel, check Group name and enter CEILING-RETURN.
h. Check Translate and set the X offset to -14 ft.
i. Press Apply and Done to copy the row of return grilles and close the panel.
Figure 24.19: Two Rows of Return Grilles in the Graphics Window
20. Create two more return grilles.
a. Click the Create grille button ( ).
b. Double click the newly created object to open the Grille panel.
c. In the Info tab, enter ceiling-return-crac1 under Name and select CEILING-RETURN
from the Groups drop-down list.
d. In the Geometry tab, set the Plane to X-Z and enter the following dimensions:
e. In the Properties tab, set the Free area ratio to 0.5.
f. Press Done to apply the settings and close the panel.
g. Right click the vent ceiling-return-crac1 from the Model tree and select Copy.
h. In the Copy group panel, check Group name and enter CEILING-RETURN.
i. Check Translate and set the Z offset to 10 ft.
j. Press Apply and Done to copy the return grille and close the panel.
k. Right click ceiling-return-crac1.1 and Rename the object to ceiling-return-crac2.
Figure 24.20: Two CRAC Return Grilles in the Graphics Window
21. Set the per-object meshing parameters for the return grilles.
b. In the Local tab, press Edit next to the Object params option.
i. In the Per-object meshing parameters panel, Shift+left click ceiling-return and then
ceiling-return.3 to select all the return grilles.
Figure 24.21: Per-object Meshing Parameters for the Return Grilles
22. Create a PDU.
a. Go to Macros Geometry Data Center Components PDU to open the Create PDU
panel.
b. Enter the dimensions as shown below in Figure 24.22: The Create PDU Panel (p. 534).
c. Set the PDU flow direction to +Y.
d. Set the Heat output to 3600 W.
e. Set the Percent open area on top and the Percent open area on bottom to 0.25.
Figure 24.22: The Create PDU Panel
f. Press Accept to create the PDU.
23. Set the per-object meshing parameters for the grilles pdu_vent_in and pdu_vent_out.
b. In the Local tab, check Object params and press Edit.
i. In the Per-object meshing parameters panel, Ctrl+left click pdu_vent_in and

pdu_vent_out to select both objects.
24. Create a new group for the PDU.
a. Select all the PDU objects by Shift+left clicking pdu_unit and then pdu_part4 in the Model
manager window.
c. In the Create group panel, enter PDUs in the Name for new group text field.
25. Create the second PDU.
a. Right click PDUs in the Groups node and select Copy.
b. In the Copy group panel, check Group name and enter PDUs.
c. Check Translate and set the X offset to 14 ft and the Z offset to 28 ft.
d. Press Apply and Done to copy the PDU and close the panel.
Figure 24.23: Two PDUs in the Graphics Window
e. Now may be another good time to Save the project ( ).
26. Create blockages.
a. Click the Create blocks button ( ).
i. Set the Name to piping and the Group to BLOCKAGE.
ii. Set the Type to Hollow.
c. Click the Create blocks button ( ).
d. In the object geometry window:
i. Set the Name to blockage and the Group to BLOCKAGE.
27. Create columns.
i. Set the Name to column1 and the Group to COLUMNS.
c. Click the Create blocks button ( ).
d. In the object geometry window:
i. Set the Name to column2 and the Group to COLUMNS.
28. Create cabletrays.
i. Set the Name to cabletray1 and the Group to CABLETRAYS.
c. Create three more cabletrays.
i. Right click CABLETRAYS in the Groups node and select Copy.
ii. In the Copy group panel, check Group name and enter CABLETRAYS.
iii. Check Translate and set the X offset to 6 ft.
iv. Press Apply and Done to copy the cabletray and close the panel.
v. Right click CABLETRAYS in the Groups node again and select Copy.
vi. In the Copy group panel, check Group name and enter CABLETRAYS.
vii. Check Translate and set the X offset to 14 ft.
viii.Press Apply and Done to copy the cabletrays and close the panel.
Figure 24.24: The Completed Model
1. Click the Generate mesh button ( ).
2. In the Mesh control panel, enter 2 ft, 0.5 ft, and 1 ft for the Max element size for x, y, and z, re-
spectively. Change the Minimum gap values to 1 in, 0.36 in, and 1 in for x, y and z, respectively.
Figure 24.25: Mesh Control Panel
Note:
The units for the Minimum Gap values are in inches.
3. Click Generate.
4. Use the Display and Quality tabs to view the mesh and check the mesh quality.
5. Click Close to close the panel once you have finished viewing the mesh.
24.8. Step 5: Create Monitor Points

Create two temperature monitor points for the CRAC fans exhaust fans by dragging crac_exhaust
and crac_exhaust.1 from the Model node to the Points node. Ansys Icepak will automatically
monitor values at the centers of these objects. The default setting is to monitor Temperature. You can
also monitor Pressure and/or Velocity by double clicking the monitor point in the Points folder and
choosing which variables to monitor at that location.
Figure 24.26: Creating Monitor Points

a. In the General setup tab:
i. Turn Off the Radiation.
ii. Select Turbulent and Zero equation for the Flow regime.
iii. Enable the Gravity vector.
b. In the Defaults tab:
i. Select Mica-Typical from the Insulators section of the Default solid drop-down list.
ii. Select Paint-non-metallic from the Paint section of the Default surface drop-down list.
c. In the Transient setup tab:
i. Set the initial Y velocity to be 0.5 ft/s (a non-zero initial velocity is recommended for
problems involving natural convection).
d. In the Advanced tab:
i. Select the Ideal gas law (recommended for problems involving significant temperature dif-
ferences).
ii. Check Operating density and keep the default value.
iii. Select Enable for Species and keep default values in the Species definitions panel.
iv. Press Accept to apply the settings and close the panel.
e. Set the RH value for the crac-intake fans.
i. Select the crac-intake fans by Ctrl+left clicking crac_intake and then crac_intake.1
in the Model manager window.
ii. Right click and select Edit from the context menu.
iii. Select Species from the Fan Flow tab located within the Fan’s [*multiple*] Properties tab
and click Edit.
iv. In the Species concentrations panel, select RH% from the concentrations list and enter 50.
v. Click Done to save your settings and close the panel.
vi. Click Done in the Fan’s [*multiple*] panel.
a. Change the Number of iterations to 1000 and the Convergence criteria for Energy to 1e-6.
b. Click Accept to apply the settings and close the panel.
a. Set the Discretization scheme for Pressure as Body Force.
b. Set the Under-relaxation to 0.2 for Momentum and to 0.1 for Body forces.
c. Set the Precision to Double.
d. Click Accept to apply the settings and close the panel.

File Save project

1. Go to Solve Run solution.
2. In the Results tab, check CFD Post/Mechanical data.
Ansys Icepak begins to calculate a solution for the model, and a separate window opens where the
Upon completion of the calculation, your residual and monitor plots will look something like Fig-
ure 24.27: Solution Residuals (p. 543) and Figure 24.28: Temperature Point Monitors (p. 544). You can
zoom in the residual plot by using the left mouse.
Note:
The actual values of the residuals may differ slightly on different machines, so your plots
may not look exactly the same as Figure 24.27: Solution Residuals (p. 543) and Fig-
ure 24.28: Temperature Point Monitors (p. 544).
Figure 24.28: Temperature Point Monitors
4. Click Done in the Solution residuals and Temperature Point monitors windows to close them.

The objective of this exercise is to consider the airflow patterns and identify problem areas such as hot
spots, stagnant zones, and recirculation zones through out the datacenter. You will accomplish this by
examining the solution using Ansys Icepak's graphical postprocessing tools.
1. Display contours of temperature on the CRACs, Racks, and PDUs.
a. Click the Object face button ( ).
b. Enter surface-temp-contours in the Name field.
c. In the Object drop-down list, expand the Groups node and Ctrl+left click CRACs, HDRACKs,
PDUs, and RACKs, and click Accept.
d. Check Show contours and click Create.
e. Click Done to close the panel.
Figure 24.29: Object Face Temperature Contours
2. Display animated contours of temperature on plane cuts in all 3 coordinate planes.
a. Right click surface-temp-contours under the Post-processing node in the Model manager
window, and make the object face inactive by unchecking Active in the context menu.
b. Click the Plane cut button ( ).
c. Enter plane-temp-contours in the Name field.
d. Check Show contours and click Create to view a plane cut of the temperature contours.
Figure 24.30: Plane Cut Temperature Contours
e. Check the Loop mode option and click Animate to display a loop of the plane cut traversing
from the min z to the max z side of the datacenter.
f. Click Interrupt on the progress bar to return to the Plane cut panel.
g. Repeat the above procedure for plane cuts in the Y-Z and X-Z planes by changing the Set
position to X plane through center and Y plane through center respectively.
h. Click Done to close the panel.
3. Display animated contours of temperature on an isosurface.
a. Right click plane-temp-contours in the Model manager window and make the plane cut
inactive by unchecking Active in the context menu.
b. Click the Isosurface button ( ).
c. Enter iso-temp in the Name field.
d. Enter 90 in the Values field.
e. Check Show contours and click Create to view the isosurface of 90°F.
Figure 24.31: Isosurface of 90°F
f. To view a loop of isosurfaces from 90°F to 80°F:
i. In the Animation group box, enter 90 for Start, 80 for End, and 10 for Steps.
ii. Check the Loop mode option and click Animate.
iii. Click Interrupt on the progress bar to return to the Isosurface panel.
g. Click Done to close the panel.
4. Display airflow patterns in the datacenter.
a. Right click iso-temp in the Model manager window and make the isosurface inactive by un-
checking Active in the context menu.
b. Click the Object face button ( ).
c. Enter airflow in the Name field.
d. In the Object drop-down list, expand the Groups node and Ctrl+left click CEILING-RETURN,
HDRACKs, PDUs, RACKs, and TILEs, and click Accept.
e. Check Show particle traces and click Parameters.
f. Set the Point distribution options to Mesh points.
g. Set the End time under Particle options to 5.
h. Check Loop mode under Animation and set the Steps to 50.
i. Click Apply to display the airflow patterns.
Note:
Ansys Icepak will take a few moments to generate the airflow patterns.
Figure 24.32: Particle Traces
j. Click Animate to visualize the airflow patterns in a transient manner.
k. View the animated airflow patterns from various angles from the Orient menu.
l. Press Interrupt to stop the animation.
m. Click Done in the Object face particles and Object face panels to close them.
n. Right click airflow in the Model manager window and make the particle traces inactive by
unchecking Active in the context menu.
5. Report the volumetric flow rate distribution at the perforated floor tiles.
a. Go to Report Summary report to open the Define summary report panel.
b. Click New to get a new field to define the Summary report.
c. In the Objects drop-down list, expand the Groups node and select TILEs, and click Accept.
d. Select Volume flow from the Value drop-down list and deselect Comb.
e. Click New to get a new field to define the Summary report.
f. In the Objects drop-down list select crac_exhaust and crac_exhaust.1, and click Accept.
g. Select Relative humidity from the Value drop-down list and deselect Comb.
h. Click Write to display the summary report.
i. Click Done to close the Report summary data panel.
j. Click Close to close the Define summary report panel.
6. Save ( ) the project and Close Ansys Icepak.
24.13. Step 10: Additional Exercise: Visualize and analyze the results in
Ansys CFD-Post
In addition to using the postprocessing tools contained within Ansys Icepak, you can also postprocess
using the advanced tools in Ansys CFD-Post through Ansys Workbench. See Postprocessing Using Ansys
CFD-Post (p. 465) for details on how to use the features in Ansys CFD-Post.

In this tutorial, you learned how to model a datacenter using macros, and how to organize a model
using groups. You also learned how to use animated postprocessing objects to examine the results.
Chapter 25: Design Modeler - Electronics
25.1. Introduction
This tutorial demonstrates how to use Ansys DesignModeler to convert a model for analysis in Ansys
Icepak.
• Use the Slice, Opening, Fan, and Simplify options in Ansys DesignModeler.
• Organize the model using Parts.
Note:
25.2. Prerequisites
• Familiarity with the Ansys Workbench interface

You will convert an imported STEP file for use in Ansys Icepak. Figure 25.1: Comparison of the Geometry
in Ansys DesignModeler and Ansys Icepak (p. 554) shows the geometry in Ansys DesignModeler before
the conversion and in Ansys Icepak after conversion.
Design Modeler - Electronics
Figure 25.1: Comparison of the Geometry in Ansys DesignModeler and Ansys Icepak

1. Open Ansys DesignModeler through Ansys Workbench.
a. Start a new Ansys Workbench session.
b. Drag a Geometry (Ansys DesignModeler) component module from the Toolbox and drop it on
the Project Schematic window as shown in Figure 25.2: Creating a Geometry Component Mod-
ule (p. 555).
c. Rename the Geometry component module to STEP Import and DME to Icepak
Translation. To rename the title, double-click the title Geometry, or click the down arrow
( ) and select the Rename option from the drop-down list.
Figure 25.2: Creating a Geometry Component Module
d. Save the project (name the project as DME).
e. Right-click the A2 cell and select New DesignModeler Geometry.

1. Go to the Units menu.
a. Ensure that you have Millimeter selected as the desired length unit.
2. Go to File Import External Geometry File and select DME.stp and press Open.
Note:
DME.stp can be found on the Ansys Help Site. The procedure to download this file is
described below.
2. Download the dme.zip file here.
3. Unzip the dme.zip file you have downloaded to your working directory.
3. Click to create the model.
Figure 25.3: Imported Model
25.6. Step 3: Add Shortcuts to the Toolbar

Add a few shortcuts to the toolbar to aid in your design process.
Step 3: Add Shortcuts to the Toolbar
1. Go to Tools Options
2. In the Options panel, go to DesignModeler Toolbars.
3. Set Slice, Freeze, and Electronics to Yes.
Figure 25.4: Options Panel
4. Press OK to add the options to the toolbar.
Note:
• The Electronics drop-down menu in the toolbar contains several options:
• You can also access the option from the Create menu.
• You can also access the and Electronics options from the Tools menu.
25.7. Step 4: Edit the Model for Ansys Icepak

1. Check which bodies are already recognized as Ansys Icepak objects.
a. Go to Electronics Show Ice Bodies. Only bodies with simple geometries recognized as Ansys
Icepak objects will be visible.
Figure 25.5: Bodies Recognized as Ansys Icepak Objects
Note:
We will not have to make modifications to export these bodies into Ansys Icepak.
b. Go to Electronics Show CAD Bodies. Only bodies with complex geometries not recognized
as Ansys Icepak native objects will be visible.
Step 4: Edit the Model for Ansys Icepak
Figure 25.6: Bodies not Recognized as Ansys Icepak Objects
Note:
These are the bodies we will have to modify in order to export these bodies into Ansys
Icepak.
c. Go to Electronics Revert View to return to the previous display.
2. Create a Slice for one set of fins.
a. In the Tree Outline, right-click Housing and select Hide All Other Bodies.
Note:
Expand the node 54 Parts, 54 Bodies to see the Housing node.
b. Select from the Shortcuts toolbar.
c. In the Details view, set the Slice feature name to FinsSlice1.
d. Select Slice by Surface for Slice Type.
e. Click the field to the right of Target Face and select the one of faces at the base of the fins, as
shown in Figure 25.7: FinsSlice1 Face Selection (p. 560) and click Apply.
Figure 25.7: FinsSlice1 Face Selection
Note:
If you cannot select the face, try using the Model Faces selection filter ( ).
f. Make sure Slice Targets is set to Selected Bodies.
g. Click the field to the right of Bodies and select the Housing body from the Tree Outline.
h. Click Apply and then .
i. Verify that the Details view for FinsSlice1 resembles Figure 25.8: Details View of FinsSlice1 (p. 560).
Figure 25.8: Details View of FinsSlice1
3. Likewise, create a Slice for the other set of fins.
a. Use the procedure described above on the other set of fins and name the second Slice FinsS-
lice2.
Note:
The Housing should now appear in several parts in the Tree Outline. When se-
lecting Hide All Other Bodies, select all of the Housing nodes first.
Note:
Make sure that the Bodies selection is the larger section of the housing containing
the fins as shown in Figure 25.9: FinsSlice2 Bodies Selection (p. 561).
Figure 25.9: FinsSlice2 Bodies Selection
4. Create Parts for the sliced fins.
Note:
The Parts will become Assemblies in Ansys Icepak.
a. Press +Y on the Triad (the axes) to get a clear view of the fins.
b. Select Box Select from the Shortcuts toolbar.
c. Select the Bodies selection filter ( ).
d. Drag the bounding box around one set of fins, and rotate the model to make sure that all the
fins are selected as shown in Figure 25.10: Selecting a Row of Fins (p. 562) (you should have 13
bodies selected).
Figure 25.10: Selecting a Row of Fins
e. Right-click anywhere in the Model View and select Form New Part.
f. In the Details view, set the Part feature name to Fins1 and press Enter on the keyboard.
g. Repeat steps a to f for the other set of fins, except name the part Fins2.
5. Simplify the Housing body between the parts Fins1 and Fins2.
a. Select the Housing body in the Tree Outline.
Important:
Note that this Housing body is located outside the parts Fins1 and Fins2.
b. Go to Electronics Simplify.
c. In the Details view, rename the feature HousingSimplify and then press Enter.
d. In the Simplification Type field, select Level 1 from the drop-down list.
e. Click Generate to finish the simplify operation.
6. Create openings for the fan and the back panel.
a. Show all bodies again by right-clicking one of the objects in the Tree Outline and clicking Show
All Bodies.
b. Use the Single Select option now along with the Faces selection filter.
c. Go to the +Y view and select the face as shown in Figure 25.11: FanOpenings Face Selec-
tion (p. 564).
Figure 25.11: FanOpenings Face Selection
d. Go to the –Y view.
e. While holding down the Ctrl key, select the face as shown in Figure 25.12: BackOpenings Face
Selection (p. 564).
Figure 25.12: BackOpenings Face Selection
f. Go to Electronics Opening.
g. In the Details view, click Apply in the Faces field. You should have 2 to the right of Faces.
h. Click Generate to finish creating the feature.
7. Create a Fan.
a. Right-click the Fan body in the Tree Outline and select Hide All Other Bodies.
Note:
If you cannot view the object correctly, press Zoom to Fit ( ).
b. Go to Electronics Fan.
c. In the Details view, set the Fan name to FanGeom.
d. Click the field to the right of Body To Extract Fan Data, select the entire fan body and click
Apply.
e. Click the field to the right of Hub/Casing Faces and select the faces as shown in Fig-
ure 25.13: Hub/Casing Faces Selection (p. 565).
Figure 25.13: Hub/Casing Faces Selection
Note:
You can select multiple faces by simultaneously holding down Ctrl and clicking the
objects.
f. Click Apply and .
Note:
Although it may seem like there was no change, this step creates a fan object in Ansys
Icepak. To confirm this, you can go to Electronics Show Ice Bodies and check if
the fan is present.
g. Add the fan to the Front-Panel part.
i. In the Tree Outline, select the Front-Panel part and then simultaneous press Ctrl and
click the Fan object.
ii. Right-click the Fan object and select Form New Part.
iii. In the Details view, rename the Front-Panel Part to Front-Panel-Fan.
8. Perform a Simplify operation on the Housing.
a. Show all bodies again by right-clicking one of the objects in the Tree Outline and clicking Show
All Bodies
b. Go to Electronics Simplify.
c. In the Details view, set the Simplify feature name to HousingFrontBack.
d. In the field to the right of Simplification Type, select Level 1.
e. Click the field to the right of Select Bodies and select the front and the rear panels of the
Housing as shown in Figure 25.14: HousingFrontBack Bodies Selection (p. 567).
Tip:
Again, simultaneously press Ctrl and click each panel in order to make both selections.
Figure 25.14: HousingFrontBack Bodies Selection
f. Click Apply and .
9. Perform a Simplify operation on the PWB and the T0220 objects.
a. Select all the Housing, Fin, Panel, Opening, and Fan objects from the bottom of the Tree
Outline by holding down Shift and clicking the objects of interest as shown in Figure 25.15: Se-
lection of Housings, Fins, Panels, Openings, and Fans (p. 568).
Figure 25.15: Selection of Housings, Fins, Panels, Openings, and Fans
Note:
Selecting Fins1, Fins2, Front-Panel, Rear-Panel, Housing includes the selection of

all the components inside of those nodes.
b. Right-click the selected objects and select Hide Body to view just the internal components.
c. Go to Electronics Simplify.
d. In the Details view, set the Simplify feature name to PWB_T0220.
e. In the field to the right of Simplification Type, select Level 1.
f. Click the field to the right of Select Bodies and select the PWB and all the HS_AF0 and
T0220_Case objects.
Tip:
You can either follow the steps immediately below to select the objects from the
Graphics window, or you can select them directly from the Tree Outline.
i. Go to the +Z view.
ii. Make sure the Select Mode is Single Select.
iii. Hold down Ctrl and select the objects as shown in Figure 25.16: PWB, HS_AF0, and T0220_Case
Bodies Selection (p. 569).
Figure 25.16: PWB, HS_AF0, and T0220_Case Bodies Selection
g. Click Apply. The Select Bodies field should now show 13 bodies selected.
h. Click .
10. Add all the package objects to the Parts.
a. Change the Selection Mode to Box Select and make sure the selection filter is set to Bodies.
b. Select a package object as shown in Figure 25.17: Package Object Selection (p. 570). There should
be 7 bodies selected.
Figure 25.17: Package Object Selection
c. Right-click the model and select Form New Part. All the bodies will be added to the part.
d. Name the part T0220_Case1.
e. Repeat steps a to e for the rest of the packages, except naming the parts T0220_Case2,
T0220_Case3, etc.
11. Perform a Simplify on the Coil.
a. Go to Electronics Simplify.
b. In the Details view, set the Simplify name to CoilAssembly.
c. In the field to the right of Simplification Type, select Level 1.
d. Click the field to the right of Select Bodies and select the bodies as shown in Figure 25.18: Coil
Bodies Selection (p. 571). There should be 4 bodies selected.
Figure 25.18: Coil Bodies Selection
e. Click Apply and .
12. Add the rest of the Coil bodies to the part.
a. Make sure the selection filter is set to Bodies.
b. Make the same selection as in the simplify operation. Notice that there are now 8 bodies instead
of 4.
c. Right-click the model and select Form New Part.
d. In the Details view, set the Part name to CoilAssembly2.
13. Perform a Simplify on the Capacitors.
a. Go to Electronics Simplify.
b. In the Details view, set the Simplify name to Capacitors.
c. In the field to the right of Simplification Type, select Level 3.
d. Click the field to the right of Select Bodies and select the bodies as shown in Figure 25.19: Ca-
pacitors Bodies Selection (p. 572). There should be 3 bodies.
Figure 25.19: Capacitors Bodies Selection
e. Click Apply.
f. Set the Facet Quality to Medium
g. Click .
14. Form a part for the Capacitors.
b. Make the same selection as the simplify operation. There should still be 3 selected bodies.
c. Right-click the model and select Form New Part.
d. In the Details view, set the Part name to Capacitors.
15. Form parts for the Heat Sink and Components.
b. Follow the same steps as before to create a part called BGAHS for the Heat Sink and Compon-
ents for the Components:
Figure 25.20: BGAHS and Components Parts Selections
16. Right-click a body in the Tree Outline and select Show All Bodies. Your model should look like
Figure 25.21: Final Model in Ansys DesignModeler (p. 574) and your Tree Outline should look like
Figure 25.22: Final Tree Outline (p. 575).
Figure 25.21: Final Model in Ansys DesignModeler
Step 5: Opening the Model in Ansys Icepak
Figure 25.22: Final Tree Outline
Note:
Some of your parts and bodies may be in a different order than what is shown in Fig-
ure 25.22: Final Tree Outline (p. 575).
17. Check if all the bodies have been converted to Ansys Icepak objects.
a. Go to Electronics Show CAD Bodies.
b. Confirm that the view contains no bodies. This means all the bodies have been recognized by
Ansys Icepak.
18. The model is now ready to use in Ansys Icepak.
25.8. Step 5: Opening the Model in Ansys Icepak

1. Go to File Save Project and then File Close DesignModeler.
2. In Ansys Workbench, drag an Ansys Icepak component to cell A2 to create an Ansys Icepak component
module.
Figure 25.23: Creating an Ansys Icepak Component Module
3. Double-click the Setup cell (B2) to open the model in Ansys Icepak.
4. In the Model manager window, right-click the Model node and select Expand all to view the
geometry inside the assemblies.
5. Notice that the bodies have been successfully transferred into Ansys Icepak.
Step 6: Summary
Figure 25.24: Final Model

In this tutorial, you learned how to get a CAD model ready for Ansys Icepak using Ansys DesignModeler.
You used the slice, simplify, openings, and fan operations to convert the model.
Chapter 26: CFD Modeling and Analysis of an Avionics
Box
26.1. Introduction
This tutorial describes the procedure for setting up and running a CFD analysis for the Ansys Icepak
geometry that was created as a part of the Design Modeler - Electronics (p. 553) tutorial located in the
Icepak Tutorial Guide.
Note:
26.2. Prerequisites
You should have the following before starting this tutorial:
• Ability to perform basic project analysis in Ansys Icepak
26.3. Create a New Ansys Icepak Project

• Open a new, standalone Icepak session and click Unpack.
Figure 26.1: Options Available for a New Icepak Session
CFD Modeling and Analysis of an Avionics Box
• In the file selection panel, select the packed project file tut26-Icepak.tzr and click Open.
Note:
The file tut26-Icepak.tzr can be found on the Ansys Help Site. The procedure to
download this file is described below.
2. Download the avionics.zip file here.
3. Unzip the avionics.zip file you have downloaded to your working directory.
Figure 26.2: File Selection Panel
• In the location for the unpacked project file selection dialog, select a location where you would like
to create the new Icepak project and click Unpack.
• Note that the faces of the cabinet align with the outermost boundaries of the rest of the model.
Create a Support for the Box and Resize Cabinet
Figure 26.3: Unpacked Model
26.4. Create a Support for the Box and Resize Cabinet
• Click to create a new block.
• From the Model manager window, double-click block.1 to open the edit panel.
• Using the Info tab, rename the block as Support and click Update.
• In the Properties tab, set the block type to Hollow as shown in the below figure:
Figure 26.4: Block Type
• In the Geometry tab, switch to Start / length, update the coordinates for the block as shown below
and click Done.
Figure 26.5: Block Dimensions
Note:
The zL dimension is in feet.
• A warning message (see below) comes up indicating that the support block is outside the cabinet.
• Click Resize cabinet to allow the cabinet to resize to include the support block within its extents.
Figure 26.6: Warning Message
• From the Model manager window, double-click Cabinet and open the Cabinet edit panel.
• In the Geometry tab, modify the cabinet dimensions as shown below and click Update.
Figure 26.7: Updated Cabinet Dimensions
• Using the Properties tab, set the Wall type for the cabinet sides as shown below and click Done.
Note:
This setup will be used for a forced convection and a natural convection (fan failure) based
analysis.
Figure 26.8: Updated Properties Tab for Cabinet
• Go to the Orient menu, select Scale to Fit to resize the view in the graphics window.
• Save using the File menu and click Save project.
26.5. Set Up the Model for Non-conformal Meshing

• Go to Orient menu and click Orient Positive Y.
• Keeping the Shift key pressed, left click and drag the mouse to draw a window around the box as
shown below. Release the left click or Shift button to select the geometry fully enclosed within the
box.
Figure 26.9: Select the Box Geometry
Set Up the Model for Non-conformal Meshing
• Right-click the selected items (in the Model manager window) and select Create assembly from the
menu items as shown below.
Figure 26.10: Create an Assembly for the Box Geometry
• In the Model manager window, expand assembly.1 by clicking the assembly node
( ).
• Note in the Model manager window that the Fan is listed outside the Front-Panel-Fan assembly
node.
• Select the Fan from the Model manager window and drag it to the Front-Panel-Fan assembly
as shown below.
Figure 26.11: Move the Fan to the Front-Panel-Fan Assembly
• The updated Model manager window is shown below.
Figure 26.12: Updated Model manager Window
• On the Model manager window, double-click assembly.1 to open the edit panel for assembly.1.
• Go to the Meshing tab and then select Mesh separately. Modify the Slack settings, Max element
size, and Minimum gap inputs as shown below and then click Done.
Figure 26.13: Slack Settings and Max Element Size Inputs for assembly.1
• Similarly, modify the slack values for the other assemblies as shown in Table 26.1: Slack Settings for
the Remaining Assemblies (p. 590).
• Also, select the Use global mesh control settings for all assemblies listed in Table 26.1: Slack Settings
for the Remaining Assemblies (p. 590).
Note:
As you have done for assembly.1, select Mesh separately in the Meshing tab for each
of the assemblies in the table before entering the required inputs.
Tip:
To facilitate the specifications, click Update in the Assemblies panel after each specification
and then click the next assembly object in the Model manager window. Doing this, you
do not have to close and re-open the Assemblies panel repeatedly.
Table 26.1: Slack Settings for the Remaining Assemblies
Assembly Min X Max X Min Y Max Y Min Z Max Z

Rear-Panel 0 0 1 1 1 1
T0220_Case3 1 1 2.23 1 1 1
T0220_Case2 1 1 1 1 1 1
T0220_Case1 1 1 1 1 1 1
T0220_Case4 1 1 2.23 1 1 1
T0220_Case5 1 1 1 1 1 1
T0220_Case6 1 1 1 1 1 1
Coil 1 1 1 1 4.175 1
Components 1 1 1 1 4.175 1
Capacitors 1 1 2.271 1 4.175 2
BGAHS 1 1 1 1 4.175 1
Fins1 1 0 1 1 1 1
Fins2 0 1 1 1 1 1
Note:
You have not meshed the Housing assembly separately. Furthermore, you have set a
few slack values to 0 for some assemblies. These are to avoid any assembly-assembly in-
tersections, which Ansys Icepak does not allow.
• For the Front-Panel-Fan assembly, modify slack settings, max element sizes, and minimum gap
settings and enable uniform mesh parameters and 2D multi-level meshing as shown in Figure 26.14: Fan
Assembly Mesh Settings (p. 592)
Figure 26.14: Fan Assembly Mesh Settings
• Save the project by going to File then selecting Save project.
26.6. Generate the Mesh

• Go to the Model menu and click Generate mesh. Ensure the Mesh type is set to Mesher-HD.
• Change the Max element size and Minimum gap settings to those shown in Figure 26.15: Mesh
Parameters (p. 593). Note that the Minimum gap settings are in mm.
Generate the Mesh
Figure 26.15: Mesh Parameters
• Click Generate. The resulting mesh size should be between 500,000 and 600,000 cells. Observe in
the Message window that no mesh exists for the DIE_AF0 objects.
• Right-click the Model node from the Model manager window and select Sort Meshing Priority.
Figure 26.16: Sorting the Model manager Window by Meshing Priority
• From the Model manager window, expand the node for the assembly TO220_Case3. Note that
DIE_AF0 is at the top of the list indicating that it has the least meshing priority.
• While holding down the Shift key, select TO220_Case_0 and TO220_Case_1 from the Model
manager window. Drag and drop these above DIE_AF0 as shown in Figure 26.17: Modifying the
Meshing Priority (p. 594). This automatically changes the respective meshing priority settings such
that DIE_AF0 has a higher meshing priority than the TO220_Case blocks do.
Note:
For more information on meshing priority, see Controlling the Meshing Order for Objects
of the Icepak User’s Guide.
Figure 26.17: Modifying the Meshing Priority
• Similarly, update the meshing priorities of the other DIE_AF0 blocks for all the TO220_Case assem-
blies.
Power and Material Inputs
• Go to the Mesh control panel and click Generate. Confirm that the Message window does not display
warnings for the meshing of the DIE_AF0 objects as it has earlier.
Note:
From the messages printed in the Message window, remeshing is limited to the
TO220_Case assemblies only.
• Use the Display and Quality tabs to visualize mesh refinement and assess mesh quality.
• Save the project.
26.7. Power and Material Inputs

• Using the Properties tab of the edit panel, update the solid material and power inputs for the blocks
as listed in Table 26.2: Material and Power Inputs (p. 595).
– You do not need to change the settings for blocks not included in this list.
Tip:
For objects that require similar material and power specifications, you can edit them sim-
ultaneously to speed up the process. From the Model manager window, select all of the
objects requiring the same material and power specifications, such as the DIE_AF0 objects,
while holding down the Ctrl key. Right-click one of the selected objects and select Edit
to open the shared object edit panel. You can now select the material and total power for
all of the selected objects simultaneously. Click Done after you change the settings.
Table 26.2: Material and Power Inputs
Node Object name Material Total Power

(W)
TO220_Case3 DIE_AF0 Ceramic_material 2
T0220_Case2 DIE_AF0.1
Coil Coil-2 Cu-Brass
Components Component Mold_material
Component.1
Component.2
Component.3
Capacitors Capacitor
Capacitor.1
Capacitor.2
BGAHS BGA Ceramic_material 5
26.8. Fan Inputs

• Specify the fan curve and swirl inputs for the Fan object as shown below. Remember that the object
Fan is located in the Front-Panel-Fan node of the Model manager window.
Note:
Orient the fan in the negative Y direction by selecting Negative in the Flow direction
group box.
Figure 26.18: Fan Curve and Swirl Inputs for the Fan Object
Physical and Numerical Settings
26.9. Physical and Numerical Settings

Set up the physical parameters of your model and the solver settings.
Problem Setup
Note:
manager window. See 2.7. Step 4: Physical and Numerical Settings (p. 28) of the Finned
Heat Sink tutorial for more instruction regarding the Problem setup wizard. You must still
use the same settings described in this tutorial for the Problem setup wizard.
• Modify the General setup tab for the Basic parameters (under the Problem setup node) as shown
below.
Figure 26.19: Basic parameters/General setup
• Set the options for discrete ordinates radiation model as below and click Accept.
Figure 26.20: DO Radiation Settings
• Go to the Defaults tab and update the Ambient conditions as shown below.
Figure 26.21: Basic parameters/Defaults
• Go to the Transient setup tab and set a Solution initialization Z velocity of 0.01 m/s as shown
below. When gravity is turned on, it is good practice to initialize the flow field with a small velocity
opposite to the gravity vector.
Figure 26.22: Basic parameters/Transient Setup
• Go to the Advanced tab, enable Solar loading and update the options for solar loading as shown
below. Click Accept.
Figure 26.23: Solar load model parameters Panel
Solver Setup
• Go to the Solve menu and click Settings Basic. Increase the Number of iterations to 500 and
click Accept.
• Retain the defaults for the Parallel and the Advanced settings.
• Create a monitor point at the centroid of the BGA. There are two ways to do so:
Method 1:
– Drag and drop the BGA block from the BGAHS assembly node in the Model manager window to
the Points node as shown below.
– Double-click the newly created monitor point and accept the default settings.
Figure 26.24: Creating a Point Monitor (Temperature) for the BGA Block - Method 1
Method 2:
– From the Model manager window, as shown below, right-click the BGA block and click Add to
Clipboard.
– Right-click the Points node (see below) and select Paste from Clipboard.
– The BGA point monitor will be added to the Points node.
Figure 26.25: Creating a Point Monitor (Temperature) for the BGA Block - Method 2
• Similarly, create monitor points for the opening objects Rear-Panel_18 and Rear-Panel_4,
found in the Rear-Panel assembly node. Modify the corresponding monitor point panels to enable
velocity and temperature monitoring during the solution process by selecting both Temperature
and Velocity check boxes for each of the rear panel monitor points.
Figure 26.26: Point Monitors (Temperature and Velocity) for the Openings Rear_Panel_18 and
Rear_Panel_4
Calculate a Solution
Save using the File menu and click Save project.
26.10. Calculate a Solution

• Go to the Solve menu and click Run solution to launch the Solve panel as shown below.
• Click Start solution.
Figure 26.27: Run Solution
• The solution should converge in fewer than 150 iterations.
Figure 26.28: Convergence and Point Monitor Plots
26.11. Examine the Results

Examine your results by creating postprocessing objects, such as temperature contours on the PWB and
Component objects.
• Go to the Orient menu and click Orient Negative Z and then click Zoom in in the Orient menu to
zoom-in on the graphical display on the box.
• As shown below, keeping the Shift key pressed, click and drag to draw a window that includes the
PWB and all the components on the board.
– The selection will also include the support block and some of the Housing blocks (cylinder blocks
at the base of the housing).
Examine the Results
Figure 26.29: Selection for Postprocessing
• Right-click the selection on the Model manager window and choose Create Object Face(s)
Combined to create contours of temperature, the default variable, on the faces of the selected objects.
• Click Done on the Object face panel.
• Review the contours display (Figure 26.30: Display Contours of Temperature on Selected Objects (p. 606)).
– Note that the hot spots are located on the capacitors and the components.
– The max Y (west) side of the support block is directly exposed to solar radiation. This is confirmed
by the results. This side is ‘warmer’ than the other sides of the support block.
Figure 26.30: Display Contours of Temperature on Selected Objects
• Right-click face.1 from the Post-processing node (in the Model manager window) and then
deselect Active to deactivate face.1.
Examine the Results
Figure 26.31: Contours of Temperature on Selected Objects
Temperature contours on a ‘clipped’ Plane Cut
• Go to the Post menu and click Postprocessing units and set the units for Length to mm.
• Go to the Post menu and click Plane cut.
• In the Plane cut panel, select Point and normal for Set position. Change the coordinates of the
point and the normal vector direction according to Figure 26.32: Plane cut Panel Settings for
cut.1 (p. 608). Click Create.
• Check Enable clipping and enter the extents for clipping as shown below (Figure 26.32: Plane cut
Panel Settings for cut.1 (p. 608)) and click Update.
Tip:
You can also snap the extents of the clipping zone from the graphics window.
• Review the contours display.
• Use the scroll bar on the Plane cut panel or click the Animate button to traverse the plane cut across
the box.
• Change the point and normal settings, in the Plane location group box, to visualize the contours in
different orientations.
• Click Parameters (adjacent to Show contours) to change the variable, color level settings, and so
on.
Figure 26.32: Plane cut Panel Settings for cut.1
Figure 26.33: Plane Cut of Temperature Contours within Avionics Box
Examine the Results
Create a field of velocity vectors on the clipped plane cut:
• Go to the Orient menu and select Orient Negative Z and then click Zoom in in the Orient menu
to zoom in on the graphical display on the box.
• In the Plane cut panel for cut.1, turn off the display of contours by deselecting Show contours.
Enable the display of vectors by selecting Show vectors.
• Update the point and normal settings for the plane cut as below:
Figure 26.34: Updated Point and Normal Settings for cut.1
• Click Parameters (adjacent to Show Vectors), set the Display options to Uniform (10000), select
the Project to plane option and click Apply then Update.
Figure 26.35: Updated Plane Cut of Velocity Vectors
• Review the vectors display.
• Use the scroll bar on the Plane cut panel and/or the Animate button to traverse the plane cut across
the box.
• Update the point and normal settings to visualize the vectors in different orientations.
• Right-click cut.1 from the Post-processing node and deselect Active to deactivate cut.1.
Streamlines from the Fan
• Expand the Inactive node on the Model manager window, right-click face.1 and click Active to
display face.1 again.
• Go to the Post menu and click Object face.
• In the Object face panel (for face.2), using the drop-down menu select the Fan as the object.
• Check Show particle traces and click Parameters.
• Update the Parameters panel for the particle traces as below and click Apply.
Examine the Results
Figure 26.36: Updated Settings for face.2
• Review the streamlines display.
Figure 26.37: Updated Graphical Display
• Use the Animate button to visualize a dynamic 3D representation of the air flow beginning from the
fan and exiting out of the openings on the rear panel.
– Adjust the steps input to modify the number of frames included in the animation.
• Deactivate face.1 and face.2.
Power and Temperature Values
• Go to the Post menu and select Power and temperature values to identify (and display) the objects
which fail for specified maximum temperature criteria.
• Assume that the maximum temperature rating for the components in this setup is 85°C.
• In the Power and temperature limit setup panel, set the Default temperature limit to 85 C and
click All to default.
• Click Show too hot to report (in the message window) and display (on the graphics window) the
objects that fail this criterion.
Additional Exercises
– The graphical display will update for standard shape Icepak objects only. CAD objects will not be
highlighted in the graphics window but will be listed in the message window instead.
Figure 26.38: Updated Graphical Display
• Close the Power and temperature limit setup panel.
• Save using the File menu and click Save project.
26.12. Additional Exercises

Setup for natural convection (fan failure)
• From the Model manager window, double-click the object Fan to open its edit panel.
• In the Properties tab, go to the Options sub-tab and check the Failed option.
• Set the Free area ratio to 0.5 and click Done.
Figure 26.39: Updated Fan Setup for Failure Mode
• Go to the Solve menu and select Settings Advanced and update the under-relaxation settings
for Pressure and Momentum to 0.7 and 0.3 respectively.
• Go to the Solve menu and click Run solution, enter a unique Solution ID and click Start solution.
Note:
The ID icepakcfd-tut2600 should not be used for the Solution ID as it has already
been used for the forced convection, steady-state simulation setup.
• Postprocess the results as done previously.
Setup for Transient Analysis – Forced Convection Mode
26.13. Setup for Transient Analysis – Forced Convection Mode
Note:
This exercise considers a transient period of 24 hours for CFD analysis and hence will be a
highly intensive undertaking from a computational standpoint. For the sake of understanding,
you may choose to run the transient solution for a shorter time period.
• Go to the Post menu and select Load solution ID, select icepakcfd-tut2600 and click Okay.
• Go to the Problem setup menu and click Basic parameters Transient setup and set the Time
variation to Transient.
• Set the Start time to 0 s and the End time to 86400 s (24 hours).
• Click Edit parameters for Transient, set the Time step to 60 s and the Solution save interval to
30.
– Based on this setting, the solver will write out the results every 1800 seconds (30 minutes) during
the solution process.
• Click Accept to close the Transient parameters panel.
Figure 26.40: Basic parameters and Transient parameters Panel Inputs
• Go to the Defaults tab.
• Set the Ambient conditions for Temperature to 1 C.
• Select the Transient option for Temperature and click Edit to open the Transient temperature
panel.
• Select the Piecewise linear type for specifying the time dependant variation of Ambient temperature.
• Click the Text editor button and enter the Time (s) vs. Ambient temperature (°C) inputs as shown
in Figure 26.41: Time Dependant Variation for Ambient Temperature (p. 616).
Figure 26.41: Time Dependant Variation for Ambient Temperature
• Click Accept, Done, and Accept to close the Curve specification, Transient temperature and Basic
parameters panels respectively.
• Go to Solve Settings Basic and set the Iterations / timestep to 200.
• Go to the Solve menu and click Run solution, enter a unique Solution ID.
• As shown below, set the Type to Restart and select the ID for the forced convection, steady-state
simulation (icepakcfd-tut2600) with the Full data option.
– Having an established flow field from the steady state analysis as a starting point will aid conver-
gence during the transient simulation.
Setup for Transient Analysis – Forced Convection Mode
Figure 26.42: Use of Steady State Simulation as the Starting Point for the Transient Simulation
• Click Start solution.
• Postprocess the transient simulation as you have done previously.
– Use the Post menu and click Transient settings to march Forward/Backward in time (by Timesteps
or by increments of time) to get a time based variation for postprocessing objects such as Plane
cut, Object face and Isosurface. The marching can be done manually using the Forward/Backward
buttons (see below) or using the Animate option.
Figure 26.43: Post/Transient Settings
• Use the Post menu and click History plot to create a Time vs Variable value plot for a specified
point location within the computational domain.
• Refer to the Transient Simulation (p. 289) tutorial located in the Icepak Tutorial Guide for more inform-
ation on set-up and postprocessing of transient simulations using Ansys Icepak.
Chapter 27: SpaceClaim - Icepak Coupling
27.1. Introduction
This tutorial demonstrates how to use Ansys SpaceClaim to convert a model for analysis in Ansys Icepak.
In this tutorial, you will learn how to use the Pull, Slice, and Simplify tools in Ansys SpaceClaim.
Note:
27.2. Prerequisites
This tutorial assumes that you have basic familiarity with the Ansys Workbench and Ansys Icepak inter-
faces.

You will use Ansys SpaceClaim to convert an imported STEP file for use in Ansys Icepak.
The input file DME.stp can be found on the Ansys Help Site. The procedure to download this file is
described below.
2. Download the dme.zip file here.
3. Unzip the dme.zip file you have downloaded to your working directory.

1. Open a new session of Ansys SpaceClaim (Start > All Programs > Ansys 2019 R2 > SCDM 2019
R2).
2. From the File menu, select Open to display the Open dialog.
3. Select STEP as the file type and navigate to your working directory where the DME.stp file is located.
4. Click Open with the default import options as shown in Figure 27.1: SpaceClaim Open Dialog (p. 620).
SpaceClaim - Icepak Coupling
Figure 27.1: SpaceClaim Open Dialog
5. The imported geometry should appear as shown in Figure 27.2: Initial Geometry in SpaceClaim (p. 620).
Figure 27.2: Initial Geometry in SpaceClaim
27.5. Clean Up the Geometry and Translate to Icepak Objects

1. Enter Select mode by activating it in the Edit toolbar, or by pressing ESC.
Clean Up the Geometry and Translate to Icepak Objects
Figure 27.3: SpaceClaim Edit Toolbar - Select Mode
2. Select any face of the housing and then right-click it. From the right-click menu, select Hide Others.
Note:
Alternatively, select a face and press Alt + H to hide all other objects. Ctrl + H hides
only the currently selected object.
Figure 27.4: Housing Face Selection
3. Use the Split Body tool to simplify the housing to prisms and cylinders.
Figure 27.5: Split Body Button
4. Select the housing body, then select one of the sides to split the fins.
Figure 27.6: Splitting the Housing and Side Fins
5. Press ESC.
6. Activate the Split Body tool again and select the other side to split the other set of fins.
7. Press H to go to the home view.
8. Select all the housing bodies and then right-click anywhere in the model display area.
9. From the right-click menu, select the color box and then Randomize Colors.
Figure 27.7: Randomize Body Colors
10. View the model. Each separate housing body now has a different color. This makes it very easy to
visually identify separate bodies.
Figure 27.8: Randomized Body Colors
11. Select any face on the central part of the Housing and press Alt + H to hide the fins.
12. Perform the split body operation detailed above on the two faces shown in Figure 27.9: Splitting
the Central Housing (p. 624).
Figure 27.9: Splitting the Central Housing
13. Select the newly split bodies and randomize their colors.
14. Press Ctrl + Shift + H to show all bodies.
Note:
Alternatively, you can right-click in the model display area and select Show All.
Figure 27.10: All Bodies
15. SpaceClaim has an auto-identify feature that quickly creates Icepak primitive objects for simple
geometry. Go to the Workbench ribbon and click Identify Objects.
Figure 27.11: Identify Objects
16. Click the green check mark button to automatically convert all the objects highlighted in red to
Icepak primitives.
Figure 27.12: Convert to Icepak Primitives
17. View the model. Notice that the icon changed in the structure tree for the bodies that were converted.
Figure 27.13: Icepak Icons in Structure Tree
18. To display the objects that still require work, use the Show > Non-Icepak Bodies function.
Figure 27.14: Non-Icepak Bodies
19. We will now use the Icepak Simplify feature to remove unnecessary geometry details and convert
to Icepak objects. There are four different levels of simplification:
• Level 0: Converts geometry to a bounding box prism.
• Level 1: Converts geometry to a collection of prisms and cylinders.
• Level 2: Converts geometry to a polygonal approximation.
• Level 3: Keeps the geometry as-is. Use only for critical objects, as mesh count can increase
substantially.
20. Select Icepak Simplify and use Level 0 for the PCB and TO packages highlighted below.
Figure 27.15: Simplify the PCB and TO Packages
21. The objects can be selected one by one, or you can also use a rectangle select. Notice that the
simplification automatically removes holes, chamfers, and fillets.
Figure 27.16: Simplified PCB and TO Packages - Level 0 Simplification
22. Now simplify the capacitors using Level 1 without the Cleanup or Allow Splitting options.
Figure 27.17: Simplified PCB and TO Packages
23. Use the Show Non-Icepak bodies command to see what remains.
Figure 27.18: Remaining Non-Icepak Bodies
24. Press ESC to go back to the Select tool, draw a box around the transformer, and use Alt + H to hide
other bodies.
Figure 27.19: Transformer
25. Use Level 2 simplification to approximate the three coil objects as polygons. Make sure to enforce
the Z axis as the extrusion direction, and disable the Allow Splitting option.
Figure 27.20: Simplified Transformer - Level 2 Simplification
Note:
For these objects, the default Points on Arc and Length Threshold options create a
reasonable approximation. When more detail is required, you can increase the Points on
Arc and reduce the Length Threshold. However, keep in mind that polygons with ex-
cessive vertices can lead to high aspect ratio mesh cells, which are usually detrimental
to solver convergence and accuracy.
26. Select any face on the core body, and right-click and select Hide Others. If necessary, press ESC to
go back to select mode.
Note:
If needed, press Ctrl + Z to undo any undesired geometry operation.
Figure 27.21: Simplified Core Body
27. Use Level 1 simplification and enable the Allow Splitting option on the core body.
Figure 27.22: Simplified Core Body - Level 1 Simplification
Sometimes the Allow Splitting option yields too many bodies. For these cases, it’s best to manually
split the original geometry before using the Simplification tool. Use Ctrl + Z to undo, and then use
the Split Body tool to separate the core as shown below.
Figure 27.23: Split the Core Body
Go back to the Level 1 simplification tool, enable Allow Splitting, and apply it to the two core
bodies. The simplification now produces a satisfactory result without excessive bodies.
Figure 27.24: Simplified Split Core Body - Level 1 Simplification
28. Use the Show Non-Icepak bodies function. Only three objects should be left: two chassis sides and
a fan.
Figure 27.25: Chassis and Fans
29. Select the chassis side with the slotted holes and hide all other bodies. It might be tempting to
import this object as Level 3 CAD. For this model, it’s probably okay to do so, but for more complex
models, importing too many objects as Level 3 can lead to a very large mesh count and a cumbersome
meshing experience.
Note:
For simple objects like this chassis side, it’s best to use Icepak meshing priority to
your advantage by creating openings for the slots and simplifying the block as a
prism. Once in Icepak, by default, the openings have a higher meshing priority and
cut out holes in the solid block.
30. Click on one face of the chassis as shown in the following image.
Figure 27.26: Chassis Face
31. From the Icepak menu shown in the following image, select Opening. Then click on the face of the
chassis that you had selected. Press ESC to exit the Opening tool.
Figure 27.27: Opening Tool
32. Use the Icepak Simplify Level 0 option to convert the chassis side to a simple prism.
Figure 27.28: Simplified Chassis Side
33. The openings previously created will cut holes through the solid chassis side prism.
34. We'll use a slightly modified approach for the remaining chassis side. Select the Front-Panel and
hide all other bodies. Copy the curves on one side.
Figure 27.29: Front Panel
35. Create faces with the Fill tool by pressing F.
Figure 27.30: Create Front Panel Faces
36. Select the three slotted faces and activate the Pull tool by pressing P.
Figure 27.31: Select Front Panel Faces
37. Turn on the No merge option. This ensures that SpaceClaim doesn’t merge the extruded bodies to
yield a single solid prism.
Figure 27.32: Enable No Merge
38. Select Up to in the Pull options as shown in Figure 27.33: Select Pull Option - Up To (p. 637).
Figure 27.33: Select Pull Option - Up To
39. Select the face on the other side of the chassis to pull the full thickness length.
Figure 27.34: Select Chassis Face
40. Rename the new solid blocks as fluid_cutout.X where X goes from 1 to 3.
Note:
To quickly find an object in the structure tree, right-click on any face and select
Locate in Structure Tree.
41. Simplify the chassis side using Level 0.
42. Simplify the fluid cutouts using Level 2. Be sure to set the Enforce axis option to the Y axis. In
Icepak, you will use meshing priority to ensure that the chassis side has these polygonal cutouts.
Figure 27.35: Simplify the Fluid Cutouts
43. In the Prepare ribbon, select Show Non-Icepak Bodies.
Figure 27.36: Non-Icepak Bodies
44. Press H to display the home view. Only the fan body should be displayed.
Figure 27.37: Fan Body
45. You will create the fan in Icepak. The fan CAD will only serve as reference geometry. Simplify the
fan using the Level 3 option.
Figure 27.38: Simplified Fan - Level 3 Simplification
46. Facet quality is not important since you will delete this block once you create the Icepak fan object
to replace it. For now, we can select faces and lines on the fan geometry in SpaceClaim and take
note of the following dimensions that are displayed at the bottom of the interface:
• Casing size: 31.75 mm
• Casing thickness: 9.53 mm
• Fan radius: 12.7 mm
• Hub radius: 4.76 mm
• Fan center: 0 mm, 178.689 mm, -47.63 mm
Figure 27.39: Fan Specifications
47. Use the Show > Icepak Bodies function and press H to display the home view. The final model
should appear as displayed in Figure 27.40: Final Converted Model (p. 640).
Figure 27.40: Final Converted Model
Open Icepak to Finalize Model Setup
27.6. Open Icepak to Finalize Model Setup

1. All of the geometry is now translated to Icepak bodies. Now, launch Ansys Workbench by going to
the Prepare ribbon and clicking Workbench.
2. Ansys Workbench opens and a Geometry cell is displayed in the Project Schematic.
3. Before proceeding, save the Workbench project by clicking Save from the File menu.
4. Right-click on cell A2 and select Transfer Data to New > Icepak.
Figure 27.41: Workbench - Transfer Data to Icepak
An Icepak module is added to the Project Schematic.
Figure 27.42: Workbench - Linked Icepak Module
5. Double-click on cell B2 to open Icepak.
6. The model is displayed in the Model Display window and the Project tree contains all the objects
imported from SpaceClaim.
Note:
In Icepak, all objects must have unique names. If there were objects with the same
name in SpaceClaim, they are automatically renamed in Icepak by appending a dot
and a number.
Figure 27.43: Model in Icepak
7. From the Edit menu, select Preferences and set the length units to mm. Select Units and mm. Click
Set as default, click Set all to defaults, and then close the panel by clicking This project. This en-
sures that all objects present in the model and those you will create going forward use mm as the
unit of length.
Figure 27.44: Edit Icepak Length Unit
8. To create the fan, first click the fan icon and double-click on the new fan in the model tree to
open the Edit panel. On the Geometry tab, set the fan type to 3D, position it in the X-Z plane, and
use the hub and casing measurements noted in SpaceClaim.
Figure 27.45: Edit Fan Object Geometry
9. The fan is now positioned exactly as the original CAD fan. Delete the original CAD fan by selecting
it in the Project tree, right-clicking it, and selecting Delete.
Note:
Ensure that you select the original CAD fan in the Project tree to delete the correct
one. Alternatively, you can deactivate the CAD fan to keep it in the inactive node
for future reference by right-clicking on it in the Project tree and deselecting Active.
Figure 27.46: Delete the CAD Fan
10. By default, all blocks are treated as solids. Select the fluid cutouts, right-click them, and select Edit.
On the Properties tab, set the Block type as Fluid. Click Done to apply the change and close the
Edit panel.
Figure 27.47: Set Fluid Cutout Block Type
27.7. Generate a Mesh

Now that the model is complete, ensure that the meshing priority reflects the design intent.
1. Open the Mesh control panel and click Generate to generate a mesh. Meshing the model as
is displays some issues that need to be resolved.
Figure 27.48: Mesh Warnings
2. The fluid cutouts must have a higher meshing priority than the Front-Panel object. Reduce
the meshing priority of the Front-Panel object by dragging it above the fluid cutouts in the
Project tree.
Step 6: Summary
Figure 27.49: Adjust Front-Panel Mesh Priority
3. Similarly, the Coil1 body needs a higher priority than the Coil-2 object.
Figure 27.50: Adjust Coil2 Mesh Priority
4. Open the Mesh control panel and click Generate to generate a mesh again. With the issues
resolved, the warnings do not appear.
Note:
Warnings are only displayed when an object is not meshed at all. Partially
meshed objects will not trigger any warnings. It is good practice to inspect for
adequate mesh resolution on all objects. The image below shows the Front-
Panel mesh when the fluid cutouts have a higher meshing priority.
Figure 27.51: Front-Panel Mesh with Fluid Cutouts

In this tutorial, you learned how to prepare a CAD model for Ansys Icepak using Ansys SpaceClaim. You
used the Pull, Fill, Slice, and Simplify operations to convert CAD shapes to Icepak bodies. Meshing
priority was used to cut out holes in solids without incurring in the use of complex CAD shapes.
Details on more advanced geometry operations possible within SpaceClaim can be found at http://
www.spaceclaim.com/en/default.aspx. Topics include, but are not limited to:
• Using geometric parameters to create response surfaces.
• Creating complex flow regions for cold plates.
• Using power selection to reduce model prep time.
• Healing geometry issues due to translation errors.
• Creating mid-surfaces to approximate geometry and reduce mesh count.
• Modeling geometry with parametric equations.
• Using the blend tool to fix problematic geometry.
• Identifying and modeling sheet metal features.
• Working with faceted geometry (STL files).
Chapter 28:Translation of MCAD Geometry to Icepak
Native Geometry Using Ansys DesignModeler
28.1. Introduction
This tutorial will help familiarize the user with the Ansys Workbench (WB) and the Ansys DesignModeler
(DM) interfaces. This tutorial uses a heat sink geometry to illustrate the various options that are available
with the simplify feature of the Ansys DesignModeler - Electronics utility.
Note:
28.2. Prerequisites
• Familiarity with integration of Ansys Icepak into Ansys Workbench
• Familiarity with Ansys DesignModeler interface
28.3. Tutorial Outline

Part 1: General Topics
• Model Description
• WB Project Schematic
• DesignModeler
• Import CAD model
Part 2: Model Conversion from CAD to Icepak:
• Summary of Simplification
• Simplification into Icepak objects - Level 0
Translation of MCAD Geometry to Icepak Native Geometry Using Ansys DesignModeler
28.4. Part 1: General Topics
Model Description
Figure 28.1: Customized Heat Sink with all Detailed Features (p. 650) shows a customized heat sink which
cools multiple components of different heights. This CAD model contains many detailed features which
may not significantly affect the fluid flow and heat transfer behavior of the heat sink, such as through
holes for screws to mount on the PCB. Hence, for CFD analysis using Icepak, removing such thermally
unimportant features at the beginning of the project can reduce model setup time and unnecessarily
fine meshing.
This simplification of CAD shapes offers the following benefits:
• You can more easily observe the model features than in the full, detailed CAD model.
• You can readily identify the features in the part that must be held constant and the portions where
they have freedom to conduct parametric trials or design of experiment studies to improve the
thermal and flow design.
• You will have less CAD-to-Icepak conversion work to do.
• You will have a better mesh with a lower mesh count.
Hence, we shall work with the defeatured CAD part shown in Figure 28.2: Defeatured customized heat
sink (p. 651)
Note:
If you plan to perform a subsequent thermal stress analysis using the temperature data from
Icepak results, you should retain the features that affect the stress analysis rather than sim-
plify them.
Figure 28.1: Customized Heat Sink with all Detailed Features
Ansys Workbench Project Schematic
Figure 28.2: Defeatured customized heat sink
28.5. Ansys Workbench Project Schematic

• From the Windows Start menu, select Start > ANSYS 2021 R2 > Workbench 2021 R2 to start a new
Ansys Workbench session.
• Go to File Save and save the project as cust-hs.
• Drag a Geometry component module from the Toolbox and drop it into the Project Schematic
window as shown in Figure 28.3: Create the Geometry Component (p. 651) below.
Figure 28.3: Create the Geometry Component
• Rename the Geometry component module to STEP Import. To rename the title, double-click the
title Geometry or click the left mouse button on the down arrow and select the Rename option from
the drop-down menu (highlighted in Figure 28.4: Rename the Geometry Component (p. 652) below).
Figure 28.4: Rename the Geometry Component
• Next, as shown in Figure 28.5: Create the Icepak Component (p. 652), select the Icepak component
module from the toolbox and drop it on cell A2 of the geometry component to establish the link
between Geometry (Ansys DesignModeler) and Ansys Icepak.
Figure 28.5: Create the Icepak Component
• This completes the schematic representation of the project workflow. The updated Project Schematic
is shown in Figure 28.6: Updated Project Schematic (p. 653) below.
CAD Model Import
Figure 28.6: Updated Project Schematic
• Save the project using File Save.
28.6. DesignModeler
• In the Project Schematic, right-click the Geometry cell (A2) and select New DesignModeler Geometry
to open DM.
• Go to Tools Options.
• In the Options panel, click the Toolbars sub-node under the DesignModeler node.
• Set Slice, Freeze, and Electronics to Yes.
• Click OK to exit the panel.
28.7. CAD Model Import

• Go to File Import External Geometry File, set file type to STEP (*.step;*.stp), select
custom-heat_sink-simplified.stp and click Open.
Note:
The file custom-heat_sink-simplified.stp can be found on the Ansys Help Site.

The procedure for downloading this file is described below.
2. Download the mcad_heatsink.zip file here.
3. Unzip the mcad_heatsink.zip file you have downloaded to your working directory.
• This creates a new import operation in the tree outline.
• Click Generate to complete the import operation.
Tip:
The key F5 is the keyboard shortcut for Generate.
Figure 28.7: Import Operation
• Rotate the model and observe the various geometric features in the imported CAD body.
Note:
Generating the model is necessary to implement the last operation performed on the
model. The Graphics window displays the changes.
• Note the updated status of the individual cells (A2 and B2) on the Workbench Project Schematic.
Figure 28.8: Project Schematic – Updated Cell Status
• In Workbench save the project using File Save.
Ansys DesignModeler- Electronics
28.8. PART 2: Model Conversion From CAD to Icepak
Summary of Simplification
Simplification is the process of converting a CAD part into a geometric fit with Icepak primitive objects.
Table 28.1: Simplification Types in DM for CAD-to-Icepak Conversion (p. 655) summarizes the four simplify
choices available in the DM Electronics utility. In addition to the simplification of CAD parts, you will
work with other DM tools that will be helpful in capturing the design intent in the Icepak model.
Table 28.1: Simplification Types in DM for CAD-to-Icepak Conversion
Simplification Type Description

Level 0 • A single bounding box block is created for each part.
• All features and internal faces are ignored.
Level 1 • Internal faces are recognized - Part is split at these faces.
• Resulting bodies are approximated as cuboids or cylindrical blocks.
Level 2 • Similar to Level 1, except that the resulting block shapes are polygonal
extrusions wherever applicable.
Level 3 • The CAD part is transferred as is.
• Results in an STL, or standard Tessellation language, representation as

an Icepak CAD block or CAD plate.
• Options for refinement of tessellation
28.9. Ansys DesignModeler- Electronics

As shown in Figure 28.9: Accessing DesignModeler Electronics (p. 656) below, you can access the elec-
tronics utility from the main menu as well as from the shortcuts toolbar (recommended).
Figure 28.9: Accessing DesignModeler Electronics
Simplify - Level 0
• Go to Electronics Show Ice bodies. The Graphics window will go blank. Now, go to Electronics
Show CAD bodies. The Graphics window will show the heat sink geometry.
Note:
Regular Icepak shapes (rectangular prisms, cylinders, uniform polygons) are recognized as
valid Icepak bodies automatically. The CAD bodies need to be converted to valid Icepak
bodies using the Electronics utility.
28.10. Simplify - Level 0
Steps in DM:
• From the shortcuts toolbar, change the geometry selection filter to Bodies.
• Select the heat sink body from either the Tree Outline or from the Graphics window (click the heat
sink geometry).
Figure 28.10: Tree Outline
• Go to Electronics Simplify.
• Note that Simplify1 shows up in the Tree Outline and the Details view is populated with
the simplified form. Go to the Details view.
• Click Apply in the Select Bodies row.
• Go to the Simplify input field and then add the prefix L0_ to the existing name so that the feature
is named L0_Simplify1. Press Enter.
• Set the Simplification Type to Level 0 using the drop-down list.
• Click to generate the model.
• A single block (corresponding to extents of the Heat Sink geometry) should appear in the Graphics
window.
Figure 28.11: Simplification Type: Level 0
Steps in Workbench
• Go to the Workbench Project Schematic.
• Change the title below the Icepak module to Icepak-Simplify-Level0. To do so, double-click
the title or select the Rename option using the drop-down menu.
• Double-click cell B2 (Setup for the Icepak module) to open Icepak.
Steps in Icepak
• Observe that the Icepak model contains one Icepak block, the default object type for the DM Elec-
tronics utility.
Simplify - Level 0
Figure 28.13: Icepak Interface for Icepak-Simplify-Level0
• Close the Icepak session.
Steps in Workbench
• Go back to the Workbench Project Schematic. Select the link from the STEP Import module to
the Icepak-Simplify-Level0 module. Press the Delete key on the keyboard to delete the link
and then click OK to ignore the warning message that appears.
28.11. Slice Tool in DM

• Go to DM. In the Tree Outline, right-click the L0_Simplify1 feature and click Suppress. This will
return you to the original heat sink CAD geometry.
• Change the Graphics window orientation to the positive-Z orientation by clicking the +Z arrow in
the global coordinate axes, as in Figure 28.15: Heat sink (p. 660) (a).
• Observe that the fins on the left side are polygonal profiles extruded through the heat sink length.
• Now rotate the model so that the top is just visible, as in Figure 28.15: Heat sink (p. 660) (b). Notice
that the right side contains rectangular pockets. To capture the heat sink features accurately, we will
model the left half with polygonal fit, and the right half with cuboidal fit.
Figure 28.15: Heat sink
• From the shortcuts toolbar, click Slice.
• In the Details view, set the Slice type to Slice by Surface.
• Re-orient the model to expose the heat sink bottom as in Figure 28.16: Selection of Slice Surface (p. 661).
• Select the median face (highlighted in green on the Graphics window) as in Figure 28.16: Selection
of Slice Surface (p. 661).
Note:
The geometry selection filter is automatically set to Faces.
• Click Apply on the Details view to confirm this selection as the target face for the slice operation.
Slice Tool in DM
Figure 28.16: Selection of Slice Surface
• Set the Slice Targets field to Selected Bodies (click the field to the right of Slice Targets). Select
the yellow bodies field (right box). The selection filter is automatically set to bodies. Select the heat
sink body. Click the Apply button to complete the selection.
Figure 28.17: Details View for Slice Operation
• Click Generate to generate the slice feature.
• Observe that the original heat sink is sliced into two bodies as in Figure 28.18: Updated Tree Outline
and Graphics Window (p. 661).
Figure 28.18: Updated Tree Outline and Graphics Window
• Confirm that the left side of the heat sink is recognized as a valid Icepak body by going to Electronics
Show Ice Bodies. The right side of the heat sink becomes invisible with this selection.
Note:
In the Tree Outline, the icon for a valid Icepak body (left half of heat sink) is similar to the
icon used for the corresponding primitive, a block in this case, in Icepak.
Figure 28.19: Show Ice Bodies, Updated Tree Outline and Graphics Window
• Next, go to Electronics Show CAD Bodies and confirm that only the right hand side of the heat
sink is visible with this selection.
Figure 28.20: Show CAD Bodies, Updated Tree Outline and Graphics Window
• Go to Electronics Revert View to make both bodies visible.
– Or select Show All Bodies from any of the context menus (right-click within the Tree Outline or
the Graphics window) to also make both bodies visible.
Slice Tool in DM
Figure 28.21: Revert View and Context Menus
• As shown in Figure 28.22: Rename the Bodies After the Slice Operation (p. 663), right-click the names
of the bodies and rename the two bodies as CUSTOM-HEAT_SINK-SIMPLIFIED-LEFT and CUS-
TOM-HEAT_SINK-SIMPLIFIED-RIGHT.
– The key F2 can also be used for renaming the bodies.
Figure 28.22: Rename the Bodies After the Slice Operation
• In the next section, we shall use different simplify operations on the child bodies (created as a result
of the Slice operation).
Steps in DM
• In DM, set the geometry selection filter to Bodies.
• Select CUSTOM-HEAT_SINK-SIMPLIFIED-RIGHT.
• Start a new simplify operation using Electronics Simplify.
• In the Details view, click Apply in the Select Bodies field.
• Rename the Simplify field as L1_Simplify2.
• Set Simplification Type to Level 1.
• Click Generate to generate the feature.
• Observe the changes in CUSTOM-HEAT_SINK-SIMPLIFIED-RIGHT (see Figure 28.23: Updated

Tree Outline and Graphics window (p. 664)). The original body is replaced with several cuboidal child
bodies.
• A new part named CUSTOM-HEAT_SINK-SIMPLIFIED-RIGHT, containing the above cuboid

bodies, is created in the Tree Outline. This occurs whenever a body is fitted with multiple child
bodies.
Figure 28.23: Updated Tree Outline and Graphics window
Steps in Workbench:
• Create a new Icepak component as shown below. Rename the Icepak component to Icepak-Sim-
plify-Level1 and establish a link between STEP Import (A2) and Icepak-Simplify-Level1
(C2).
Simplify - Level 1
• Double-click cell C2 (Setup for the Icepak module Icepak-Simplify-Level1) to open Icepak.
Steps in Icepak:
• Observe the Icepak model.
• Notice that CUSTOM-HEAT_SINK-SIMPLIED-LEFT is automatically translated to a corresponding

polygonal block shape in Icepak.
– Recall that Simplify operation is not required for regular Icepak shapes such as prisms, cylinders,
uniform polygons, and so on.
– If you do not wish to apply the automatically recognized shape, you can use DM to simplify the
CAD geometry as required.
– It is good practice to use simplification operations for all bodies that must be transferred to Icepak.
• The part CUSTOM-HEAT_SINK-SIMPLIED-RIGHT shows up as an Icepak assembly with the same

name. Expand the assembly to view the contents on the Model manager window and the graphics
window as shown in Figure 28.25: Icepak interface for Icepak-Simplify-Level1 (p. 666).
Figure 28.25: Icepak interface for Icepak-Simplify-Level1
• Close Icepak.
Steps in Workbench
• Go back to the Workbench Project Schematic. Select the link from STEP Import to Icepak-
Simplify-Level1 module. Press the Delete key to delete the link and click OK to ignore the
warning message that appears.
Simplification into Icepak Objects – Level 3

• Recall that the Simplify - Level 2 feature is similar to Simplify - Level 1, except that the resulting
block shapes are polygonal extrusions whenever applicable.
• The procedure for Simplify - Level 2 is identical to the procedures discussed above for Simplify -
Level 0 or Simplify - Level 1, with the exception of the Simplification Type field, which must be
set to Level 2.
• For this project, only the body at the left of Figure 28.18: Updated Tree Outline and Graphics Win-
dow (p. 661) has a meaningful polygonal shape. Since Ansys Icepak automatically recognizes this
shape as a polygon block, the default shape, you do not need to define the simplification for this
body explicitly.
28.14. Simplification into Icepak Objects – Level 3

• Go to DM. Suppress the Slice1 feature, which also suppresses L1_Simplify2. This brings back
the original heat sink geometry.Figure 28.27: Updated Tree Outline (p. 668) shows the updated Tree
Outline.
• Rename the heat sink part as CUSTOM-HEAT_SINK_SIMPLIFIED.
Figure 28.27: Updated Tree Outline
• Set the geometry selection filter to Bodies.
• Select the heat sink body and create a new Simplify operation.
• In the Details view, click Apply in the select bodies field.
• Rename the Simplify field as L3_Simplify3.
• Set the Simplification Type to Level 3.
• Set the Facet Quality to Very coarse.
• Click Generate to create the feature.
• Toggle between Electronics Show Ice Bodies and Electronics Show CAD Bodies to confirm
that the entire heat sink geometry has been converted to a valid Icepak body. You should not see
any objects in the Graphics window after selecting Show CAD Bodies.
Figure 28.28: Updated Tree Outline and Details View for L3_Simplify3
Steps in Workbench
(D2).
• Double-click cell D2 (Setup for the Icepak component Icepak-Simplify-Level3) to open Icepak.
Steps in Icepak
• Examine the Icepak model.
• Notice that the model is identical to the original CAD import.
• Check the Icepak geometry information of the only block- note that the shape is set to CAD. This is
an Icepak CAD block.
Note:
Since all the sides of this part were planar, the facet quality of very coarse was sufficient.
On the other hand, if the original CAD part contained more complex surfaces, such as b-
spline, torus, or partial or toroid cylinders, a finer resolution option might be required.
Conclusion
• Close Icepak.
Steps in Workbench
• Go back to Workbench and save the project using File Save.
28.15. Conclusion
In this tutorial, you:
• Learned how to use DM to convert a CAD part into an Icepak model
• Became better acquainted with the different levels of simplification available within the DM Electronics
utility
• Used the Slice feature multiple times in DM
Chapter 29: Simple Geometry Import Using
SpaceClaim
29.1. Introduction
This tutorial demonstrates how to use Ansys SpaceClaim to convert a heat sink model for analysis in
Ansys Icepak.
In this tutorial, you will learn how to use the Icepak Simplify and Split Body tools in Ansys SpaceClaim.
Note:
29.2. Prerequisites
This tutorial assumes that you have basic familiarity with the Ansys Workbench and Ansys Icepak inter-
faces.

You will use Ansys SpaceClaim to convert an imported STEP file for use in Ansys Icepak.
The input file custom-heat_sink-simplified.stp can be found on the Ansys Help Site. The
procedure to download this file is described below.
2. Download the mcad_heatsink.zip file here.
3. Unzip the mcad_heatsink.zip file you have downloaded to your working directory.

1. Open a new session of Ansys SpaceClaim (Start > All Programs > Ansys 2019 R2 > SCDM 2019
R2).
2. From the File menu, select Open to display the Open dialog.
Simple Geometry Import Using SpaceClaim
3. Select STEP as the file type and navigate to your working directory where the custom-
heat_sink_simplified.stp file is located.
4. Click Open with the default import options as shown in Figure 29.1: SpaceClaim Open Dialog (p. 674).
Figure 29.1: SpaceClaim Open Dialog
5. The imported geometry should appear as shown in Figure 29.2: Initial Geometry in SpaceClaim (p. 674).
Figure 29.2: Initial Geometry in SpaceClaim
Simplify - Level 0
Steps in SpaceClaim:
First, oversimplify the geometry as just a bounding box.
1. On the Workbench tab in the Icepak toolbar, click Icepak Simplify.
Figure 29.3: Icepak Simplify
2. Under Simplification Type in the Options, select Level 0 (bounding box).
3. Under Level 0 Options, select Preserve original.
Figure 29.4: Simplification Options -Level 0
4. In the graphics window, click on the heat sink geometry. A single block (corresponding to extents
of the Heat Sink geometry) appears in the graphics window, and a block is added to the Structure
tree.
5. In the Icepak toolbar, select Icepak Bodies from the Show drop-down list.
6. In the Ansys Workbench toolbar, click the 19.0 button to start Ansys Workbench.
Steps in Workbench:
1. Go to the Workbench Project Schematic.
2. Rename the Geometry component module to STEP Import. To rename the title, double-click
the title Geometry or click the left mouse button on the down arrow and select the Rename option
from the drop-down menu
3. Select the Icepak component module from the toolbox and drop it on cell A2 of the geometry
component to establish the link between Geometry (SpaceClaim) and Icepak. Alternatively, you can
right-click on cell A2, select Transfer Data to New > Icepak.
4. Name the Icepak component module Icepak-Simplify-Level0.
5. Double-click cell B2 (Setup for the Icepak module) to open Icepak.
Steps in Icepak:
1. Observe that the Icepak model contains one Icepak block, the default object type for SpaceClaim.
Simplify - Level 0
Note:
You can display object names by going to View > Display > Object names. To change
the background color go to Edit > Preferences > Display.
2. Close the Icepak session.
Steps in Workbench:
1. Go back to the Workbench Project Schematic. Select the link from the STEP Import module to
the Icepak-Simplify-Level0 module. Press the Delete key on the keyboard to delete the link
and then click OK to ignore the warning message that appears.
2. Save the project using File > Save.
29.6. Split Body Tool in SpaceClaim

1. Go to SpaceClaim.
2. In the Structure tree, select the CUSTOM-HEAT_SINK-SIMPLIFIED Icepak body with the red
block icon and press Delete. Then, select the CUSTOM-HEAT_SINK-SIMPLIFIED non-Icepak
body. If this body is not visible in the Graphics window, select the checkbox next to its name in
the Structure tree.
3. On the Design tab in the Clipboard toolbar, click the copy button and then the paste button. A
copy of the CUSTOM-HEAT_SINK-SIMPLIFIED body appears in the Structure tree. You can also
select the body in the Structure tree and use the shortcuts Ctrl+C followed by Ctrl+V on the key-
board.
4. Right-click on one of the CUSTOM-HEAT_SINK-SIMPLIFIED bodies and select Rename. Rename

the body to CUSTOM-HEAT_SINK-SIMPLIFIED-ORIGINAL.
5. In the Structure tree, deselect the check box next to CUSTOM-HEAT_SINK-SIMPLIFIED-ORI-

GINAL to hide the body.
6. Change the Graphics window orientation to the positive-Z orientation by clicking the +Z arrow in
the global coordinate axes, as in Figure 29.10: Heat sink (p. 678) (a). Observe that the fins on the left
side are polygonal profiles extruded through the heat sink length.
7. On the Design tab in the Orient toolbar, select Spin. You can also directly spin the model with the
middle mouse button.
8. Now rotate the model so that the top is just visible, as in Figure 29.10: Heat sink (p. 678) (b). Notice
that the right side contains rectangular pockets. To capture the heat sink features accurately, we
will model the left half with polygonal fit, and the right half with cuboidal fit.
Figure 29.10: Heat sink
9. Re-orient the model to expose the heat sink bottom as in Figure 29.11: Selection of Surface (p. 679).
10. In the Intersect toolbar, click Split Body.
11. Click the heat sink geometry to select it as the target body, anad then select the median face
(highlighted in orange in the graphics window) as in Figure 29.11: Selection of Surface (p. 679). The
geometry is split in the graphics window, and the Structure tree is updated.
Split Body Tool in SpaceClaim
Figure 29.11: Selection of Surface
12. Press Esc on the keyboard to exit the Split Body tool.
13. On the Workbench tab in the Icepak toolbar, click Identify Objects.
Figure 29.12: Convert to Icepak Primitives
14. Click the green checkmark button to convert the identified body to an Icepak object. The Structure
tree is updated.
15. Press Esc.
Figure 29.13: Show Icepak Bodies, Updated Structure Tree, and Graphics Window
17. In the Structure tree, select the check box next to CUSTOM-HEAT_SINK-SIMPLIFIED to show
the body.
18. On the Design tab in the Orient toolbar, click Home.
19. In the Structure tree, rename both sides of the heat sink as shown in Figure 29.14: Show Icepak
Bodies, Updated Structure Tree, and Graphics Window (p. 680).
Figure 29.14: Show Icepak Bodies, Updated Structure Tree, and Graphics Window
In the next section, we will use different simplify operations on the child bodies (created as a result
of the Split Body operation).
Steps in SpaceClaim
2. Under Simplification Type in the Options, select Level 1 (cuboid, cylindrical fit).
Simplify - Level 1
3. Under Level 1 Options, ensure that Preserve original, Allow splitting, and Randomize color are
selected.
4. In the graphics window, click on the CUSTOM-HEAT_SINK-SIMPLIFIED-RIGHT geometry.
5. Press Esc.
6. In the Structure tree, use the Shift button to select all of the newly created bodies. Right-click on
the selection and select Move to New Component. The newly created bodies are listed under a
new component. Rename the component to CUSTOM-HEAT_SINK-SIMPLIFIED-RIGHT.
Figure 29.15: Level 1 Simplification - New Component
8. On the File tab, click Save.
Steps in Workbench
1. Go to the Workbench Project Schematic.
2. Right-click on the Geometry cell A2 and select Update.
3. Create a new Icepak component as shown below. Rename the Icepak component to Icepak-
Simplify-Level1 and establish a link between STEP Import (A2) and Icepak-Simplify-
Level1 (C2).
5. Double-click cell C2 (Setup for the Icepak module Icepak-Simplify-Level1) to open Icepak.
Steps in Icepak:
1. Observe the Icepak model.
2. Notice that CUSTOM-HEAT_SINK-SIMPLIED-LEFT is automatically translated to a corresponding

polygonal block shape in Icepak.
• Recall that Icepak Simplify operation is not required for regular Icepak shapes such as prisms,
cylinders, uniform polygons, and so on.
• If you do not wish to apply the automatically recognized shape, you can use SpaceClaim to sim-
plify the CAD geometry as required.
• To reduce mesh count and increase mesh quality, it is good practice to use simplification operations
for all bodies that must be transferred to Icepak.
3. The part CUSTOM-HEAT_SINK-SIMPLIED-RIGHT shows up as an Icepak assembly with the same

name. Expand the assembly to view the contents on the Model manager window and the graphics
window as shown in Figure 29.17: Icepak interface for Icepak-Simplify-Level1 (p. 683).
Simplify - Level 1
Figure 29.17: Icepak interface for Icepak-Simplify-Level1
4. Close Icepak.
Steps in Workbench
1. Go back to the Workbench Project Schematic. Select the link from STEP Import to Icepak-
Simplify-Level1 module. Press the Delete key to delete the link and click OK to ignore the
warning message that appears.

• Recall that the Simplify - Level 2 feature is similar to Simplify - Level 1, except that the resulting
block shapes are polygonal extrusions whenever applicable.
• The procedure for Simplify - Level 2 is identical to the procedures discussed above for Simplify -
Level 0 or Simplify - Level 1, with the exception of the Simplification Type field, which must be
set to Level 2.
• For this project, only the body at the left of Figure 28.18: Updated Tree Outline and Graphics Win-
dow (p. 661) has a meaningful polygonal shape. Since Ansys Icepak automatically recognizes this
shape as a polygon block, the default shape, you do not need to define the simplification for this
body explicitly.
• In some cases you must explicitly use Simplify - Level 2 and enforce the axis in the correct direction
to obtain the desired polygonal extrusion.
29.9. Simplification into Icepak Objects – Level 3
Steps in SpaceClaim
1. In the Structure tree, delete the CUSTOM-HEAT_SINK-SIMPLIED-LEFT and CUSTOM-
HEAT_SINK-SIMPLIED-RIGHT bodies.
2. Select the check box next to CUSTOM-HEAT_SINK-SIMPLIED-ORIGINAL to display the orignal

geometry.
4. Under Simplification Type in the Options, select Level 3 (CAD object).
5. Under Level 3 Options, move the Facet Quality slider to the left to set a very coarse facet quality.
Figure 29.19: Simplification Options -Level 3
6. In the graphics window, click on the CUSTOM-HEAT_SINK-SIMPLIFIED-ORIGINAL geometry.

A preview of the facets is displayed on the body and remain visible until you exit the tool.
Figure 29.20: Updated Project Schematic and Facets Preview
7. Press Esc.
8. On the File tab, click Save.
Steps in Workbench
• Right-click on the Geometry cell A2 and select Update.
(D2).
• Double-click cell D2 (Setup for the Icepak component Icepak-Simplify-Level3) to open Icepak.
Steps in Icepak
– Examine the Icepak model.
– Notice that the model is identical to the original CAD import.
– Check the Icepak geometry information of the only block- note that the shape is set to CAD. This
is an Icepak CAD block.
Note:
Since all the sides of this part were planar, the facet quality of very coarse was sufficient.
On the other hand, if the original CAD part contained more complex surfaces, such as
b-spline, torus, or partial or toroid cylinders, a finer resolution option might be required.
It is good practice to examine CAD object facet quality in Icepak by setting the display
type to Solid.
Step 6: Summary
– Close Icepak.
Steps in Workbench
• Go back to Workbench and save the project using File >Save.

In this tutorial, you:
• Learned how to use SpaceClaim to convert a CAD part into an Icepak model
• Became better acquainted with the different simplification levels available within SpaceClaim
• Used the Split Body feature in SpaceClaim
Details on more advanced geometry operations possible within SpaceClaim can be found at http://
www.spaceclaim.com/en/default.aspx. Topics include, but are not limited to:
• Using geometric parameters to create response surfaces.
• Creating complex flow regions for cold plates.
• Using power selection to reduce model prep time.
• Healing geometry issues due to translation errors.
• Creating mid-surfaces to approximate geometry and reduce mesh count.
• Modeling geometry with parametric equations.
• Using the blend tool to fix problematic geometry.
• Identifying and modeling sheet metal features.
• Working with faceted geometry (STL files).
Chapter 30: Translation of System-Level MCAD
Geometry to Icepak Native Geometry Using Ansys
DesignModeler
30.1. Introduction
This tutorial describes procedures in Ansys DesignModeler (DM) that enable you to work more efficiently
with assembly-level CAD models. The tutorial will discuss various aspects of model organization in DM
as well as illustrate the use of DM toward conversion of the CAD geometry to a native Ansys Icepak
representation.
Note:
30.2. Prerequisites
To use this tutorial more effectively, you should have the following:
• Completion of the tutorial Translation of MCAD Geometry to Icepak Native Geometry Using Ansys
DesignModeler (p. 649) in the Icepak Tutorials
• Familiarity with the Ansys Workbench (WB) and DM interfaces
– Ansys Icepak - Ansys Workbench Integration Tutorial (p. 447) in the Icepak Tutorials
– Design Modeler - Electronics (p. 553) in the Icepak Tutorials
• Familiarity with the conversion of CAD objects into Icepak native objects
30.3. Tutorial Outline

This tutorial covers the following topics:
• Description of the model
• Import of the CAD model
• Studying of the CAD model
• Organization and simplification of the imported CAD model
Translation of System-Level MCAD Geometry to Icepak Native Geometry Using Ansys
DesignModeler
30.4. Model Description

This tutorial will consider a system-level electronics box (see figure below) for efficient conversion to
Icepak native geometry. The box consists of several parts such as the chassis, motherboard, CPU box,
fan system, memory, and so on.
Figure 30.1: Electronics Box Model
30.5. Getting Started – Ansys Workbench, Project Schematic

• From the Windows Start menu, select Start > ANSYS 2021 R2 > Workbench 2021 R2 to start a new
Ansys Workbench session.
• Go to File Save and save the project as DME-Icepak-SystemLevel.
• Go to Tools Options Appearance. Scroll down and select the Beta Options check box.
– This tutorial requires the use of the Solid Extension feature, which is currently available as a beta
feature in DM.
Getting Started – Ansys Workbench, Project Schematic
Figure 30.2: Turning On Beta Options
• Drag a Geometry component module from the Toolbox and drop it into the Project Schematic
window as shown in Figure 30.3: Create the Geometry Component (p. 692).
DesignModeler
Figure 30.3: Create the Geometry Component
• Rename the Geometry component module to MCAD.
• Select the Icepak component module from the Toolbox and drop it on cell A2 of MCAD to establish
a link between Ansys DesignModeler and Ansys Icepak.
• Rename the Icepak component module to CFD.
• This completes the schematic representation of the project workflow. Figure 30.4: Updated Project
Schematic (p. 692) shows the updated Project Schematic.
Import of CAD Geometry
30.6. Getting Started - Ansys DesignModeler

• In the Project Schematic, right-click cell A2, of the MCAD component module, and select New
DesignModeler Geometry to open DM.
• Go to Tools Options. Click the Units node and select Millimeter for the Length Unit.
• While you are still in the Options panel, go to the Toolbars node. Set Slice, Freeze, Electronics,
Analysis Tools, Repair, Face Delete and Concept Modeling to Yes to make these utilities available
in the Shortcuts Toolbar as shown below.
Figure 30.5: Sample Layout for DM Shortcuts Toolbar
30.7. Import of CAD Geometry

• In DM, go to File Import External Geometry File..., set file type to STEP (*.step;*stp),
select generic-electronic-box.stp and click Open.
Note:
The file generic-electronic-box.stp can be found on the Ansys Help Site. The
procedure for downloading this file is described below.
2. Download the mcad_board.zip file here.
3. Unzip the mcad_board.zip file you have downloaded to your working directory.
• This creates a new import operation in the Tree Outline.
• In the Shortcuts Toolbar, click Generate to complete the import operation.
DesignModeler
Figure 30.6: Updated Tree Outline and Graphics Window
30.8. Initial Model Review

• Observe the various geometric features in the imported CAD geometry.
– Use mouse movements and context menu options (Hide Body, Hide All Other Bodies, Show
Body, and Show All Bodies) as needed.
• In the Tree Outline, go to the 69 Parts, 69 Bodies node.
• The description indicates that there are 69 Parts and 69 Bodies in this setup.
• Expand the 69 Parts, 69 Bodies node and observe that although the node shows 69 parts, these are
not multi-body parts.
Initial Model Review
– For all practical purposes, the DM geometry, at this point, does not contain any parts. With DM,
this is true for any newly imported CAD geometry.
Note:
As a part of the import operation in DM, all the CAD parts from the original CAD model
are retained in the correct locations as DM Bodies. However, the organization of the
CAD assemblies (irrespective of the import source) cannot be preserved in DM.
Figure 30.7: Tree Outline
• Examine which objects are already recognized as compatible with Icepak native geometry.
1. Go to Electronics Show Ice Bodies. This feature displays only those CAD bodies that have
been recognized by DM as valid for translation to Icepak.
2. Since no simplify operations have been performed yet, only the simple shape bodies are recognized
as valid for translation to Icepak at this instance.
3. Figure 30.8: DM Bodies Compatible with Icepak Native Geometry (p. 696) shows the bodies that
can be directly converted to Icepak native geometry without simplification in DesignModeler.
DesignModeler
Figure 30.8: DM Bodies Compatible with Icepak Native Geometry
4. Go to Electronics Revert View to return to the full model view.
Note:
Using Show Ice Bodies also updates the icons for the Icepak-compatible bodies in the
Tree Outline.
30.9. CAD Geometry Information and Repair Utilities

Key Question: Is there a need to repair the imported MCAD geometry?
• CAD-to-DM translation can return incomplete, corrupt, or disconnected geometry.
• As shown below, the Analysis Tools and Repair utilities in DM can be used to fix incomplete or
corrupt geometry and connect disconnected geometry.
Note:
The geometry used in this tutorial does not need any repair.
Suppress Non-Essential Bodies
Figure 30.9: Repair and Analysis Tools Utilities in DM
30.10. Suppress Non-Essential Bodies

Key Question: Is it necessary to model all the bodies present in the CAD setup?
• Objects like screws, bolts, nuts, washers, springs, and so on have negligible influence on the heat
transfer physics of a given problem and hence can be completely ignored for the CFD analysis.
• From the Tree Outline, holding down the Ctrl key, click all of the screws, bolts, nuts, and washers
to select them simultaneously.
• Right-click the selection and click Form New Part.
• Rename the newly formed part to Fasteners.
• Right-click Fasteners and click Suppress Part to deactivate the geometry for the rest of the ana-
lysis.
DesignModeler
Figure 30.10: Create and Suppress Fasteners, Updated Graphical Display
Note:
Generally, fasteners are non-essential for the CFD analysis. However, you must be careful
to include any heat spreading objects. Also, if combined thermo-mechanical analysis with
Ansys Icepak and Ansys Mechanical is planned, it is possible that some of the fasteners
are important for FEA purposes. In this case, you should include these fasteners in both
Ansys Icepak and Ansys Mechanical.
30.11. Functionality Based Grouping

Key Question: What functionality does the object serve? Can bodies be grouped by functionality?
• The overall design of a product is usually conducted in terms of the different modules in the product,
each module performing a unique task. In the lifetime of a product, changes in design are likely to
be conducted in terms of the various functional modules.
• For a system-level setup, models can be quickly organized in terms of the functionality of the various
bodies.
• Since Ansys Icepak addresses the thermal and flow design aspects of the overall product design, it
is adequate to create DM parts that approximately correspond to the different functional modules.
Often, a functional module can be modeled by itself for detailed analysis.
• Based on this understanding, create additional parts as shown below:
Simple Shapes vs. Complex Shapes
Figure 30.11: Collapsed and Expanded Views for Newly Created Parts
Note:
During the creation of parts, in case any objects are missed, create a separate part out of
those and then merge this part with the intended part. To merge multiple parts, which
can be a combination of suppressed and unsuppressed parts, hold down the Ctrl key while
selecting the parts that need to be merged, and then right-click the selection and select
Form New Part to complete the merging of the parts. Rename the newly formed part as
appropriate.
• This completes the initial review and organization of the CAD model for efficient translation to native
Ansys Icepak geometry.
• Save the project using File Save Project in DM.
30.12. Simple Shapes vs. Complex Shapes

Key Question: Are all the bodies simple shapes? Are there any complex shapes?
• Icepak primitive shapes are recognized as simple shapes for the DM-Icepak translation.
• Level 0, 1, or 2 from the Electronics Simplify operation in DM can be used for the translation of
simple shapes to Icepak native geometry.
DesignModeler
• Simple shapes such as rectangular prisms, cylinders, and uniform polygons are automatically converted
over to Icepak (the default Icepak primitive is the solid block type).
• Go to WB and double-click cell B2 (the Setup cell from CFD module) to open the Icepak interface.
• In Icepak, go to the Orient menu and select the Isometric view and then Scale to fit to reorient the
graphics display.
• Observe that the valid Ice bodies have been successfully converted to Icepak block objects.
Figure 30.12: Show Ice Bodies in DM (left) and Model with Same Objects in Icepak (right)
• Save the project using File Save project in Icepak.
• Go back to the DM interface.
• Go to Electronics Show CAD Bodies. This feature displays only those CAD bodies that need ad-
ditional work (modification of CAD geometry and/or defeaturing of CAD geometry and/or use of
Electronics/Simplify utility in DM).
Figure 30.13: Show CAD Bodies – Updated Graphics Display for DM
• The Level 3 Simplify feature is used only for complex shapes which cannot be modeled as Icepak
primitive shapes.
Translation of CAD Bodies to Ansys Icepak
– You must use the hex-dominant mesher (Mesher-HD) to mesh these shapes in Icepak.
– Typically, complex shapes require more meshing effort. You should investigate the possibility of
approximating a complex-shaped CAD body by a simpler shape without noticeably affecting the
heat transfer physics.
Figure 30.14: Examples of Complex Shapes from Tutorial Geometry - Sheet Metal Heat Sink for
QFP1 Package and Flow Guide for Fan System
30.13. Translation of CAD Bodies to Ansys Icepak

• In DM, on the Tree Outline, collapse all part nodes as shown below.
Figure 30.15: Updated Tree Outline/Parts, Bodies View
• For the sake of clarity, it is useful to display only the part that is currently of interest and hide all
other parts and bodies.
• A “Periphery to Center Marching” strategy will be employed to target the easily visible CAD bodies
for translation to Icepak native geometry progressively.
•Translating the Chassis geometry

– In the Tree Outline, right-click the Chassis part and select Hide All Other Bodies so that only
the Chassis geometry is visible in the graphics display.
DesignModeler
Figure 30.16: Retain Only the Chassis Geometry in the Graphics Display Window
Chassis:
– DM – Electronics/Opening
→ Observe the circular through-hole at the top of the chassis and the two grilles made of rectan-
gular and circular hole patterns on the side walls of the chassis. These will be represented as
free openings in Icepak.
→ Go to Electronics Opening.
→ From the graphics window, select the three chassis faces as shown below in Figure 30.17: Opening
Operation for Chassis – Selection of Candidate Faces (p. 702).
Figure 30.17: Opening Operation for Chassis – Selection of Candidate Faces
→ In the Details view for the opening operation, click Apply to accept this selection for the Faces
field.
→ Click Generate to create the openings.
→ Observe the new entries in the Tree Outline. One new surface body and two new parts have
been created.
→ From the Tree Outline, right-click each of these newly created parts and surface body listings
to rename them as shown below.
Figure 30.18: Newly Created Parts and Surface Body
→ Merge COVER_Inlet, HOUSING_Circ_Openings, and HOUSING_Rect_Openings with

the Chassis part.
• To merge the parts, select all four parts, Chassis; COVER_Inlet; HOUSING_Circ_Open-
ings; and HOUSING_Rect_Openings, right-click and then select Form New Part. Rename
the part as Chassis.
Figure 30.19: Updated Tree Outline/Parts, Bodies View
Chassis:
– DM – Electronics/Simplify
→ On the Shortcuts Toolbar, set the Selection Filter to Bodies.
→ From the graphics display area, select the two Chassis bodies, as shown in Figure 30.20: Select-
ing Chassis Cover and Housing (p. 704), by holding down the Ctrl key.
• The same selection can also be made by expanding the node corresponding to the Chassis
part listing in the Tree Outline and selecting the bodies (using the Shift key) COVER and
HOUSING.
DesignModeler
Figure 30.20: Selecting Chassis Cover and Housing
• Go to Electronics Simplify and click Apply in the Details view to accept this selection.
• In the Details view, set the Simplification Type to Level 1
• Click Generate.
• In the Tree Outline, select Chassis and the two new parts, COVER and HOUSING, and right-
click the selection. From the right-click menu, select Form New Part. Ensure the name of the
part is Chassis.
• Observe the simplified representation of the Chassis on the graphics display.
Figure 30.21: Updated Graphical Display in DM
Chassis:
– DM – Suppress All Other Parts
→ Collapse the Chassis node on the Tree Outline.
→ From the Tree Outline, as shown below, select all the parts other than Chassis and
Fasteners, right-click the selection and click Suppress Body. The Fasteners part need not be
selected as it is already in a suppressed state.
→ The suppressing of all other parts allows the selective transfer of the (simplified) Chassis geometry
to Icepak.
Figure 30.22: Suppressing All Parts Other Than Chassis and Updated Tree Outline View
Chassis:
– Icepak – Chassis Import
→ Go to the Icepak interface.
→ Go to File Refresh Input Data and click Replace model on the Refresh input data pop-up
screen (see below) to replace the existing Icepak model.
→ Figure 30.23: Replace the Existing Icepak Model
→ In Icepak, verify that only the Chassis assembly shows up in the Model manager window.
→ From the Model manager window, expand the Chassis assembly node to view the contents.
→ Verify, from the Model manager window and from the graphics display, that all the Chassis
bodies, surface bodies and solid bodies, have been correctly translated to corresponding opening
and block objects in Icepak.
DesignModeler
→ Figure 30.24: Updated Icepak Graphics Display (p. 706) shows the isometric view of the Chassis
representation in Icepak:
Figure 30.24: Updated Icepak Graphics Display
→ Save the project using the File menu and select Save project in Icepak.
→ Go to File Close Icepak to close the Icepak interface.
Chassis:
– WB – Update Project Schematic
→ Go back to the WB interface and delete the link between the MCAD and the CFD modules as
shown in Figure 30.25: Delete Link Between MCAD and CFD Modules (p. 706).
• Doing so preserves the simplified Chassis geometry representation in Icepak for separate
analysis despite any new changes to the MCAD module.
Figure 30.25: Delete Link Between MCAD and CFD Modules
• Rename the CFD module as CFD-Chassis.
• Drag a new Icepak component from the WB Toolbox and drop on cell A2 of the MCAD module
to create a new DM-Icepak link.
• Rename the newly created Icepak module as CFD-Motherboard.
Note:
This new link will be used to process the Motherboard part in DM for translation
to native Icepak geometry.
• Save the project using File Save in WB.
Figure 30.26: Updated WB Project Schematic
• Go back to the DM interface.
• In the Tree Outline, right-click the Chassis part and select Suppress Part.
• Next, as shown below right-click the Motherboard part and select Unsuppress Part to make
only the Motherboard part geometry visible on the graphics display and available for further
processing.
Figure 30.27: Unsuppress Motherboard Part and Updated Graphics Display
Motherboard:
→ In the Shortcuts Toolbar, set the Selection Filter to Bodies.
DesignModeler
→ Also, as shown in Figure 30.28: Set Select Mode to Box Select (p. 708), on the Shortcuts Toolbar,
set the Select Mode to Box Select. Note the change in the cursor display.
Figure 30.28: Set Select Mode to Box Select
→ Draw a box to include all the Motherboard part geometry. As shown below, the selected
geometry will be shaded solid (zero transparency).
Note:
You can also select the Motherboard bodies by selecting the node Motherboard
from the Tree Outline.
Figure 30.29: Use Box Select to Select All the Geometry From the Motherboard Part
→ Go to Electronics Simplify and click Apply in the Details view to accept this selection.
→ In the Details view, set the Simplification Type to Level 0.
→ Click Generate.
→ Observe the simplified representation of the Motherboard part geometry in the graphics display.
→ You have successfully converted all the bodies from the Motherboard part to valid Ice bodies.
→ Go to Electronics Show CAD Bodies and confirm that the corresponding graphics display
is empty.
→ Go back to Electronics Show Ice Bodies.
Figure 30.30: Simplified Representation of Motherboard Part Geometry
Motherboard:
– Icepak – Import Motherboard Geometry
→ Go back to the WB interface
→ Double-click cell C2 (the Setup cell for the CFD-Motherboard module) to open Icepak.
→ In Icepak, verify that only the Motherboard assembly is visible in the Model manager window.
→ From the Model manager window, expand the Motherboard assembly node to view the
contents.
→ Verify that all the bodies from the Motherboard part in DM have been correctly converted to
corresponding block objects in Icepak.
→ The isometric view of the Motherboard representation in Icepak is shown below.
→ Go to File menu and select Close Icepak to close the Icepak interface.
Motherboard:
→ Go back to the WB interface and delete the link between the MCAD and the CFD-Motherboard
modules.
DesignModeler
→ Drag a new Icepak component from the WB Toolbox and drop on cell A2 of the MCAD module
to create a new DM-Icepak link.
→ Rename the newly created Icepak module as CFD-QFP1.
→ This new link will be used to process the QFP-1 part in DM for translation to native Icepak
geometry.
→ Save the project using File Save in WB.
•Translating the QFP-1 Part Geometry

– Go back to the DM interface.
– In the Tree Outline, suppress the Motherboard part and unsuppress the QFP-1 part.
Figure 30.33: Updated Graphics Display in DM
QFP-1:
→ From the Tree Outline, expand the node corresponding to the QFP-1 part.
→ Observe that there are two bodies (SM-HEATSINK and QFP-1) listed under this part. Here, SM-
HEATSINK represents the sheet metal heatsink and QFP-1 represents the IC package.
→ Simplify the SM-HEATSINK body with a level 3 Simplify operation.
• In the Details view for this Simplify operation, set the Facet quality to Fine. Click Generate
to complete the simplify operation.
→ Simplify the QFP-1 body using a level 0 Simplify operation. Click Generate to complete the
simplify operation.
DesignModeler
Figure 30.34: Updated Tree Outline Listing and Simplified Representation for QFP-1 Part
– Using cell D2 (the Setup cell for the CFD-QFP1 module) from the WB Project Schematic, open
Icepak.
– Verify that all the bodies from the QFP-1 part in DM have been correctly converted to corresponding
block objects in Icepak.
– Double-click SM-HEATSINK from the Model manager window to access the Edit panel for this
block. Go to the Geometry tab and note that the geometry shape is set to CAD.
→ This will always be the case when the level for simplification in DM is set to Level 3.
– Click Done to close the Edit panel for SM-HEATSINK.
– The isometric view of the QFP-1 representation in Icepak is shown below.
– Go to the File menu and select Close Icepak to close the Icepak interface.
QFP-1:
→ As before, delete the link between the MCAD and the CFD-QFP1 modules.
→ Link a new Icepak module named CFD-CPU-Box to MCAD.
•Translating the CPU-Box Part Geometry

– In the Tree Outline, suppress the QFP-1 part and unsuppress the CPU-Box part.
– Review the CPU-Box part geometry
→ From the Tree Outline, expand the node corresponding to the CPU-Box part.
→ As shown below, the CPU-Box part consists of four bodies.
DesignModeler
Figure 30.37: Updated Tree Outline View and Graphics Display in DM (Iso and +Z views)
→ Display one body at a time using the Hide function. Since the bodies contain geometric features
that are important for thermal analysis, it is a good practice to examine them and determine
how to capture the features in the CFD model.
→ CPU_Socket: Observe that CPU_Socket contains a cavity in the center. When the CPU is
mounted, the air pocket in this cavity reduces the heat flow from the CPU to the PCB. It is im-
portant to capture the effect of this air pocket. Simplification using the level 1 simplification
scheme will not recognize this cavity automatically. A new volume body will be created to
model the cavity explicitly.
Figure 30.38: CPU_Socket Body
→ TIM: Note the small thickness of TIM between the heat sink base and the CPU case. To avoid
unnecessary mesh refinement due to this small thickness, the TIM body will be set up as a
contact resistance plate in Icepak.
CPU-Box:
– DM - Filling the Cavity Within CPU_SOCKET
→ Use the Hide All Other Bodies function so that only the CPU_SOCKET body is visible on the
graphics display.
→ Use Single Select again instead of Box Select.
→ Set the selection filter to Faces.
→ Using the Ctrl key, select all the inside faces that correspond to the cavity. The selected faces
are highlighted in green (see below) in the graphics display.
Note:
You should have 8 faces selected in total. Rotate the model in order to select all of
the faces.
Figure 30.39: CPU_Socket Body – Select Cavity Faces
→ Go to Tools Fill and click Apply in the corresponding Details view (see below) to accept the
selection.
→ Click Generate.
Figure 30.40: Details View for Fill Operation
→ In the Tree Outline, select the newly generate body named Solid and verify that it accurately
represents the cavity within the CPU_SOCKET body.
→ Rename the body Solid to Socket_Cavity.
DesignModeler
Figure 30.41: Body Representing Cavity in CPU_SOCKET
→ Merge the body Socket_Cavity with the CPU-Box part by selecting both of them in the
Tree Outline and then clicking Form New Part.
Figure 30.42: Updated Tree Outline Node — CPU-Box
CPU-Box:
– TIM as a Surface Body in DM (Plate in Icepak)
→ Hide CPU_SOCKET and Socket_Cavity. Show CPU and TIM again.
Figure 30.43: Updated Graphics Display
→ Select the Selection Filter to Edges.
→ Select any one of the short edges (corresponding to the thickness) of the body TIM.
→ Go to Tools Analysis Tools Entity Information to report the detailed information for the
selected edge in the Details view.
→ Note that the length of the edge, or the thickness of TIM, is 0.254 mm.
→ Right-click the body CPU and select Hide All Other Bodies.
→ Suppress the TIM body.
Figure 30.44: Use of Analysis Tools to Find Out TIM Thickness
→ Reducing TIM into a 2D representation (surface body in DM and plate in Icepak) will leave a
0.254 mm gap, which must be filled by one of the neighboring objects (HEAT_SINK or CPU).
→ Hence, placement of the 2D TIM surface body on the CPU body will require extension of the
HEAT_SINK base by 0.254 mm.
• The additional 0.254 mm of aluminum (the HEAT_SINK material) only marginally increases
the overall thermal resistance and hence is an acceptable approximation.
• Alternatively, the placement of the 2D TIM on the HEAT_SINK body, which requires the ex-
tension of CPU, or somewhere in-between, which would require the extension of both CPU
and HEAT_SINK, can also be considered.
→ Go to the main menu and then select Concept Surface from Faces.
→ Select the top side of the CPU body (as shown below).
→ Click Apply in the Details view to accept this selection.
→ Click Generate.
DesignModeler
Figure 30.45: Creation of Surface Body for TIM
→ Note that a new surface body named CPU shows up within the CPU-Box part in the Tree Outline.
→ Rename the new surface body as TIM_plate.
Figure 30.46: Updated Tree Outline View
CPU-Box:
– DM - Extend Heat_Sink Body
→ Right-click the HEAT_SINK body and hide all other bodies.
→ Set the Selection Filter to Faces.
→ Select the bottom face of the HEAT_SINK body as shown below.
→ Go to Tools Solid Extension (Beta).
→ In the Details view, click Apply to accept the face selection.
→ Set the FD1, Offset field to 0.000254 m.
→ Click Generate.
Figure 30.47: Use of Solid Extension
→ Go back to the +Z view.
→ Right-click the CPU body and select Show Body.
→ Note that the gap (introduced due to the suppressing of the original TIM body) is now filled
with HEAT_SINK body material as shown in Figure 30.48: Before and After Use of Solid Exten-
sion (p. 719).
Figure 30.48: Before and After Use of Solid Extension
CPU-Box:
– DM - Electronics/Simplify
→ From the Tree Outline, right-click the part CPU-Box and then select Show All Bodies.
→ Go back to the +Z view.
→ Go to Electronics Simplify.
→ Using Box Select, select all the visible bodies from the graphical display. You should have 5
bodies selected.
→ Click Apply in the Details view to accept the selection.
→ Set the Simplification Level to Level 1.
DesignModeler
→ Click Generate.
Figure 30.49: Level 1 Simplification for CPU-Box Part
→ From the Tree Outline, note the newly created parts.
→ Merge the newly created parts with the CPU-Box part as shown in Figure 30.50: Merge Newly
Created Parts into CPU-Box Part, Updated Tree Outline View (p. 720).
Figure 30.50: Merge Newly Created Parts into CPU-Box Part, Updated Tree Outline View
CPU-Box:
– Icepak - Import CPU-Box Part Geometry
→ Using cell E2 (the Setup cell for the CFD-CPU-Box module) from the WB Project Schematic,
open Icepak.
→ Verify that all the bodies (except the TIM_plate body) from the CPU-Box part in DM have
been correctly converted to corresponding block objects in Icepak.
Note:
The TIM_plate surface body is represented as a plate object in Icepak.
→ The isometric view of the CPU-Box part representation in Icepak is shown in Figure 30.51: Updated
Icepak Graphics Display (p. 721).
• The TIM_plate plate object has been highlighted using View Default shading Selected
solid feature in Icepak.
→ Go to the File menu and select Close Icepak to close the Icepak interface.
CPU-Box:
– WB- Update Project Schematic
→ As before, delete the link between the MCAD and the CFD-CPU-Box modules.
→ Link a new Icepak module named CFD-Fan-System to MCAD.
→ Save the project using the File menu, click Save in WB.
DesignModeler
•Translating the Fan-System Part Geometry

– Go back to the DM interface
– In the Tree Outline, suppress the CPU-Box part and unsuppress the Fan-system part.
– Review the Fan-system part geometry
→ From the Tree Outline, expand the node corresponding to the Fan-system part.
→ Observe that the Fan-system part consists of two bodies:FLOW_GUIDE and NIDEC_D34776,
the fan.
Figure 30.53: Updated Tree Outline View and Graphics Display in DM (Iso view)
Fan-system:
– DM - Electronics/Fan
→ Go to Electronics Fan.
→ Note that the Selection Filter has automatically switched to Bodies.
→ Observe the Details view.
→ In the Shortcuts Toolbar, set Select Mode to Single Select. Note the change in the cursor display.
→ For the Body to Extract Fan Data field, select the fan housing geometry from the graphics display
as shown in Figure 30.54: Electronics/Fan – Selection of Body to Extract Fan Data (p. 723). Altern-
atively, you can simply select NIDEC_D34667 from the Tree Outline.
Figure 30.54: Electronics/Fan – Selection of Body to Extract Fan Data
→ Click Apply to accept the selection.
→ In the Details view, go to Hub/Casing Faces. This corresponds to the cylindrical faces of the
fan bore and the hub. These will be converted into the fan radius and hub radius in the corres-
ponding Icepak fan object.
→ While holding down the Ctrl key, select the two faces as shown in Figure 30.55: Electronics/Fan
– Selection of Hub/Casing Faces (p. 724). The order of face selection does not matter.
DesignModeler
Figure 30.55: Electronics/Fan – Selection of Hub/Casing Faces
→ Click Apply to accept the selection.
→ Click Generate.
→ Go to Electronics Show CAD Bodies.
→ Observe that the NIDEC_D34667 fan geometry is no longer visible. This indicates that you have
successfully translated the fan geometry between DM and Icepak.
Figure 30.56: Updated Graphics Display in DM (Iso view)
Fan-system:
– DM - FLOW_GUIDE - Simplification Strategy
→ Review the FLOW_GUIDE geometry.
→ The FLOW_GUIDE is a thin body with a thickness of 1 millimeter or less.
→ The top of the flow guide is planar and has an opening. The sides expand non-uniformly and
with a curvature. The final “base” sides are also planar.
→ To minimize the mesh, the FLOW-GUIDE body will be represented using zero thickness plate
objects in Icepak.
• The planar sides and the top opening will be modeled as simple Icepak objects.
• The expansion has a complex shape which can only be modeled as a CAD plate.
→ To retain the exact flow volume within the FLOW_GUIDE, the plates will be constructed using
inner faces of the FLOW_GUIDE body.
Fan-system:
– DM - FLOW_GUIDE Top Side
→ In DM, set the Selection Filter to Faces.
→ Select the inner face of the top side of the FLOW_GUIDE body as shown in Figure 30.57: Inner
Face of the Top Side of the FLOW_GUIDE Body, Electronics/Opening (p. 725).
Figure 30.57: Inner Face of the Top Side of the FLOW_GUIDE Body, Electronics/Opening
→ Go to Electronics Opening.
→ In the Details view, click Apply to accept the selection.
→ Click Generate.
→ Note that a new surface body named FLOW_GUIDE_1 has been created.
→ From the Tree Outline, merge this surface body with the Fan-system part.
DesignModeler
→ Set the Selection Filter to Edges.
→ As shown below in Figure 30.59: FLOW_GUIDE – Selection of Outer Edges for Inner Face of Top
Side (p. 726), select the four outer edges, highlighted in green, of the inner face of the top side
of the FLOW_GUIDE body. You should have 4 edges selected.
Figure 30.59: FLOW_GUIDE – Selection of Outer Edges for Inner Face of Top Side
→ Go to the Concept menu and select Surfaces From Edges.
→ Click Generate.
→ Note that a new surface body named Surface Body has been created at the bottom of the
Tree Outline.
Figure 30.60: FLOW_GUIDE – New Surface Body Created Using ‘Surfaces from Edges’
→ Rename Surface Body as Flow_Guide_Top_Face.
→ From the Tree Outline, merge Flow_Guide_Top_Face with the Fan-system part.
Fan-system:
– DM - FLOW_GUIDE - Non-Uniform and Base Sides
→ From the graphics display as shown below, select the inner faces of the non-uniform sides of
the FLOW_GUIDE body. You should have 4 faces selected.
DesignModeler
Figure 30.62: Inner Faces of Non-Uniform Sides of FLOW_GUIDE Body
→ Go to the Concept menu and select Surface From Faces.
→ Click Generate.
→ From the Tree Outline, note that a new surface body named FLOW_GUIDE has been created
within the Fan-system part.
→ Rename this surface body to Flow_Guide_Non-Uniform-Face.
→ Go to the View menu and select Wireframe to better visualize the newly created surface body.
Figure 30.63: Newly Created Surface Body – Flow_Guide_Non-Uniform-Face
→ Using the same procedure, create surface bodies using the inner faces of the base sides of the
FLOW_GUIDE body.
Note:
You should have had 2 faces selected.
→ After clicking Generate, rename the resulting surface bodies as shown in Fig-
ure 30.64: FLOW_GUIDE Base Sides – Newly Created Surface Bodies (p. 729).
Figure 30.64: FLOW_GUIDE Base Sides – Newly Created Surface Bodies
→ Using the level 3 Simplify operation, convert the Flow_Guide_Non-Uniform-Face surface

body to a CAD plate representation in Icepak.
• Set the Facet Quality in the Details view to Very Fine for this simplify operation. Click Gen-
erate to complete the Simplify operation.
→ The surface bodies Flow_Guide_Base_Face1 and Flow_Guide_Base_Face2 are simple

shapes and hence are automatically recognized as plates in Icepak.
→ Go to Electronics Show CAD Bodies and note that only the original FLOW_GUIDE body is
visible.
→ Suppress the FLOW_GUIDE body.
→ Go to Electronics Show Ice Bodies.
→ Go back to the Shaded Exterior and Edges view using the View menu.
DesignModeler
Figure 30.65: Updated Tree Outline and Graphics Display
Fan-system:
– Icepak - Import Fan-system Part Geometry
→ Using cell F2 (the Setup cell for the CFD-Fan-System module) from the WB Project Schem-
atic, open Icepak.
→ Verify that all the bodies from the Fan-system part in DM have been correctly converted to
the corresponding fan, opening, and plate objects in Icepak.
Note:
The Flow_Guide_Non-Uniform-Face plate object has a CAD-type geometry.
→ The isometric view of the Fan-system part representation in Icepak is shown below.
• The View Default Shading Solid feature is used to show the solid rendering of the
Icepak geometry:
Fan-system:
– WB - Update Project Schematic
→ As before, delete the link between the MCAD and the CFD-Fan-System modules.
→ Link a new Icepak module named CFD-Memory to MCAD.
→ Right-click the white space in the Project Schematic window and select the Fit option to resize
the Project Schematic display.
DesignModeler
•Translating the Memory Part Geometry

– In the Tree Outline, suppress the Fan-system part and unsuppress the Memory part.
– Review the Memory part geometry.
→ From the Tree Outline, expand the node corresponding to the Memory part.
→ As shown below, the Memory part consists of several bodies.
Figure 30.68: Updated Tree Outline View and Graphics Display in DM (Iso and +Z views)
– Note:
The DIMM_SOCKET-1 surface bodies will not be used in the Icepak setup and hence
can be suppressed.
Suppress the four DIMM_SOCKET-1 surface bodies.
Memory:
– DM - Electronics/Simplify Level 1
→ From the Tree Outline, hide the DIMM_HS4 body and the two DIMM_TIM bodies.
→ Use the level 1 Simplify operation to simplify the DIMM body and the two DIMM_SOCKET
bodies.
DesignModeler
Figure 30.70: Level 1 Simplification of DIMM, DIMM_SOCKET Bodies
→ From the Tree Outline, merge the newly created parts, as shown in Figure 30.71: Updated Tree
Outline View (p. 734), with the Memory part. Name the merged part Memory again.
→ Rename the DIMM_8 body as DIMM_PCB and the remaining DIMM bodies as DIMM_IC as shown:
Memory:
– DM - Surface Bodies for DIMM_TIM
→ Select the two DIMM_TIM bodies.
→ Right-click the selection and click Hide All Other Bodies as shown in Figure 30.72: Updated Tree
Outline and Graphics Display (p. 736).
DesignModeler
→ The DIMM_TIM bodies will be modeled as contact resistance plates in Icepak and hence need
to be represented as surface bodies in DM.
→ While holding down the Ctrl key, select the inner faces for the two DIMM_TIM bodies as shown
in Figure 30.73: Selection of Inner Faces for DIMM_TIM Bodies (p. 736). The inner surfaces are in
contact with: the casing tops of all the DIMM_IC bodies and the opposite side of DIMM_PCB.
The design intent is to model the contact resistances at these locations; therefore it is important
to select the two inner faces for this feature operation.
Figure 30.73: Selection of Inner Faces for DIMM_TIM Bodies
→ Use the Concept menu and select Surfaces From Faces to create corresponding surface bodies.
Click Apply in the Details view and then click Generate.
→ Note that two new surface bodies named DIMM_TIM are now listed within the Memory part
listing in the Tree Outline.
• Since the newly created surface bodies are simple shapes, they are automatically recognized
as valid Icepak plate objects.
→ Rename these bodies to DIMM_TIM_Plate1 and DIMM_TIM_Plate2 respectively.
→ Suppress the two original DIMM_TIM bodies.
Memory:
– DM - Recreate DIMM_HS4 and Simplify Using Electronics/Simplify
Level 3
→ Show the DIMM_HS4 body. Now the DIMM_HS4, DIMM_TIM_Plate1, and DIMM_TIM_Plate2
bodies are visible.
→ Go back to the +Z view and zoom in as shown in Figure 30.75: Updated Graphics Display and
Zoom-in +Z View (p. 738).
DesignModeler
Figure 30.75: Updated Graphics Display and Zoom-in +Z View
→ Note that there is a small gap between the DIMM_TIM_Plate surface bodies and the DIMM_HS4
body.
→ This gap equals the thickness of the original DIMM_TIM body, which is 0.0776 mm.
• This gap can be measured using Analysis Tools /Distance Finder or Analysis Tools /Entity
Information.
→ This gap will be removed by re-creating the heatsink.
→ Pick any thin edge of the DIMM-HS4 body and find its thickness using Analysis Tools /Entity
Information.
• It is 0.5 mm thick. Thus the total thickness from the outer surface of DIMM_HS4 to the
DIMM_TIM_Plate (nearest to the selected surface) is 0.0005776 m.
→ From the graphics display, as shown below, select any outer face of DIMM_HS4.
→ From the Shortcuts toolbar use the Extended Selection feature (see Figure 30.76: Recreating
the Heatsink Geometry (p. 739)) and select Extend to Limits. This will select all the outer faces
of Heat sink.
→ Go to the Create menu and select Thin/Surface.
→ In the Details view, set the Selection Type to Faces to Keep.
→ Click Apply in the Details view to accept the face selection.
• Make sure that 17 faces are selected.
→ Set the Direction field to Inward and the field FD1, Thickness (>=0) to 0.5776 mm.
→ Click Generate.
Figure 30.76: Recreating the Heatsink Geometry
→ Observe that the gap between the DIMM_HS4 body and the DIMM_TIM_Plate surface bodies
no longer exists.
→ Using the level 3 Simplify operation, simplify the DIMM_HS4 body for a CAD-type block repres-
entation in Icepak.
• Set the Facet Quality in the Details view to Very Fine for this Simplify operation. Click
Generate to complete this operation.
Memory:
– Icepak - Import Memory Part Geometry
→ Using cell G2 (the Setup cell for the CFD-Memory module) from the WB Project Schematic,
open Icepak.
→ Verify that all the bodies from the Memory part in DM have been correctly converted to the
corresponding block and plate objects in Icepak.
Note:
The DIMM_HS4 block object has a CAD-type geometry.
→ The isometric view of the Memory part representation in Icepak is shown in Figure 30.77: Updated
Icepak Graphics Display (p. 740).
DesignModeler
• The View Default shading Solid/Wire feature was used to display the solid rendering
in Icepak.
Memory:
→ As before, delete the link between the MCAD and the CFD-Memory modules.
→ Link a new Icepak module named CFD-System to MCAD.
→ Right-click the white space in the Project Schematic window and select the Fit option to resize
the Project Schematic modules.
DesignModeler
•System-Level Setup in Icepak

– Go back back to the DM interface.
– Unsuppress all of the parts except for Fasteners.
– Go to the WB interface.
– Using cell H2 (the Setup cell for the CFD-System module) from the WB Project Schematic, open
Icepak.
– Verify that all the bodies from the DM setup have been correctly converted to corresponding block,
plate, fan, opening objects in Icepak.
Figure 30.79: Updated DM Tree Outline, DM Graphics Display, Icepak Graphics Display
– Go to the File menu and select Close Icepak to close the Icepak interface.
– Save the project using File Save in WB.
– The MCAD-Icepak translation for this system-level electronics box setup is now complete.
– Exit out of WB using File Exit.
30.14. Summary
In this tutorial, the following features/capabilities have been discussed:
• Use of Ansys Workbench to integrate DM with Icepak
• Import and organization of assembly level CAD models in DM
• Use of DM for modification and simplification of imported CAD geometry
• Translation of CAD geometry to Icepak primitive objects using DM Electronics
Chapter 31: MRF Tutorial
31.1. Introduction
The purpose of this tutorial is to provide guidelines and recommendations for the Moving Reference
Frame (MRF) fan modeling technique in Ansys Icepak. These guidelines and recommendations concern
the areas of
• Problem Setup
• Meshing strategy, and
• Solver settings
Note:
31.2. Prerequisites
• Familiarity with Icepak interface, and having a good understanding of basic problem setup and
solution procedure.
An Icepak 3D fan object may sometimes behave differently from real fan behavior. Typically this is due
to flow features like swirl and centrifugal spread resultant from the spinning fan rotor as well as the
rotor blade geometry. In an Icepak fan based setup, this swirl is estimated and calculated off a 2D an-
nular flow face rather than off the physical surfaces of the blade.
The MRF approach allows for a more accurate representation of the internal geometry of the fan and
therefore results in a better modeling of the flow features. In Icepak MRF simulations, the actual blade
geometry is modeled as a CAD block object and a fluid cylinder rotates into contact with the surfaces
to create a spinning flow.
In this tutorial, you will use a previously built Icepak model of fan blades (Figure 31.1: A 3D Icepak Fan
Object Assembly (p. 744)a) and create the rotating MRF fluid blocks to create flow in the model. You
will learn the proper problem setup and solution settings for an MRF model, as well as a good meshing
technique to insure good results.
As an added bonus, a 3D Icepak fan object assembly (Figure 31.1: A 3D Icepak Fan Object Assembly
(p. 744)b) can be activated and run to see the difference in flow patterns and results.
MRF Tutorial
Figure 31.1: A 3D Icepak Fan Object Assembly
31.3. Opening the Project

• Start Icepak by either double clicking the shortcut on your desktop or by going to Start >> All programs
>> Ansys 2019 R2 and selecting the independent Ansys Icepak.
• Once Icepak has launched, click on the Unpack button.
Note:
In Icepak, models can be compressed into a specialized zip file with the extension tzr. This
is called “packing” a project. The essential files needed to properly re-build the model, in-
cluding the mesh settings, are saved in this compressed file. A model has been previously
created to reduce the time needed to properly teach the MRF techniques in Icepak and
will be opened out of this packed file.
• Download the file “MRF_Tutorial.tzr” and select this file to unpack. You will then be able to create a
project folder for this tutorial. Choose the location and name the project “MRF_Practice”.
Note:
MRF_Tutorial.tzr can be found on the Ansys Help Site. The procedure for downloading this
file is described below.
2. Download the mrf.zip file here.
3. Unzip the mrf.zip file you have downloaded to your working directory.
Modifying the Geometry
• Next, go to the Model menu and select CAD data. Click None under Families to turn off the CAD
display.
• Set the orientation to the isometric view to display the model geometry as shown below.
Figure 31.2: Unpacked Model Geometry
31.4. Modifying the Geometry

• Under the Inactive node in the Model tree, there are four assemblies. Two are remnants of the
openings used to create the inlet and exhaust grilles. The others are the MRF fan and Icepak 3D fan
assemblies.
• Select the “FANS_CAD.1” assembly and activate it.
Note:
You can activate the assembly by selecting it and then using the Ctrl A shortcut or by
right clicking and selecting Active.
• An assembly containing the CAD fan blades (rotors), fan casing blocks, and fan tray cutout blocks
should appear.
MRF Tutorial
• Expand the FANS_CAD.1 assembly node on the Model tree to view the fan blade geometry.
• Click on any object inside of the FANS_CAD.1 assembly and create two fluid blocks surrounding the
fan blades and cutting through the casing blocks using the information provided in Table 31.1: Fluid
Block Settings for MRF Setup (p. 746) below.
Table 31.1: Fluid Block Settings for MRF Setup
Name Shape Plane Center Height Radius Type

FluidA Cylinder Y-Z xC:141.3 mm 20.0 mm 34.0 mm Fluid
yC:133.04 mm
zC:130.6 mm
FluidB Cylinder Y-Z xC:141.3 mm 20.0 mm 34.0 mm Fluid
yC:133.04 mm
zC:56.6 mm
Note:
If your current object selection is not inside of the assembly, the new fluid cylinders would
appear outside and have to be dragged into the assembly. This is saving this extra step.
Another time saver would be to create FluidA and then copy the object. You would just
need to change the name of the copy to FluidB and change the zC location.
• As shown in Figure 31.3: Fluid Blocks Surrounding Fan Blade Geometry (p. 747), the fluid cylinder
blocks will be created at the bottom of the assembly list. This is because Icepak will, by default, give
the newest objects the highest meshing priority. The fluid blocks need to have a higher priority than
the case blocks but a LOWER priority than the fan rotor so that the rotor will be fully meshed. To
automatically change the meshing priority, highlight both these fluid cylinders in the Model tree,
and drag them above the fan blades (drop them on top of the upper most blade). The assembly
should now look like Figure 31.4: Updated Model Tree View (p. 747).
• Double click on FluidA in the Model tree. Under the Properties tab, select Use rotation for MRF
and set a rotational speed of 6000 as seen in Figure 31.5: MRF Settings (p. 748). Repeat this for FluidB.
Important notes for MRF fan modeling technique:
• Using the exact fan blade geometry is critical for the accuracy of the MRF fan modeling technique.
If the fan housing contains straightening vanes, these must also be modeled with their exact geomet-
ries.
• The rotation rpm here refers to the rotation of the fan rotor and blades. The direction follows the
right hand thumb rule.
Modifying the Geometry
Figure 31.3: Fluid Blocks Surrounding Fan Blade Geometry
Figure 31.4: Updated Model Tree View
MRF Tutorial
Figure 31.5: MRF Settings
31.5. Generating the Mesh
• To start, go to the global mesh settings panel by clicking on the shortcut and ensure the mesh
type is Mesher-HD.
• Set the Minimum gap values to 1 mm in all directions and update the dialog to look like Fig-
ure 31.6: Global Mesh Settings (p. 749).
Note:
HD meshing starts with a default hexa-unstructured mesh, and progressively uses other
element types (tetrahedral, etc.) in areas where geometric complexity does not allow for
Generating the Mesh
a good mesh with hexa elements. This “mesh mixing” occurs automatically in the meshing
algorithm.
Note:
Proper resolution of CAD objects requires more mesh. Resolving surfaces with curvatures
typically requires more mesh than planar faces.
Figure 31.6: Global Mesh Settings
MRF Tutorial
Meshing the MRF Fans

• To keep the mesh count as low as possible, change the Block type of the two rotor blocks
(FAN70153_1–1.1 and FAN70152_1–1.1) to Hollow.
• To restrict the finer mesh to the region immediately surrounding the fans, a non-conformal mesh
should be used. Double click the “FANS_CAD.1” assembly and go to the Meshing tab. Select the
Mesh separately option and enter the slack settings as shown in Figure 31.7: Non-conformal Mesh
Settings for FANS_CAD.1 Assembly (p. 751). Then, deselect Use global mesh control settings, click
Copy global, and enter max element sizes and minimum gap settings as shown in Figure 31.7: Non-
conformal Mesh Settings for FANS_CAD.1 Assembly (p. 751).
Note:
The positive slack values define the distance off the outermost surfaces of all objects in
the assembly. While Ansys Icepak v13.0 does allow for zero slack specification, you should
use a positive value in MRF cases to ensure good mesh transition from solid surfaces into
the fluid.
• Turn on the Allow multi-level meshing option, ensure Proximity size function and Curvature size
function are selected. Ensure the Set uniform mesh params option is enabled and set to Use average.
Note:
The Set uniform mesh params option will block off regions around complex geometries
and allow for a better mesh transition.
• Click on the Edit levels button in the Multi-level tab and set the meshing levels as shown in Fig-
ure 31.8: “Edit Levels” Settings for FANS_CAD.1 Assembly (p. 752).
Note:
Multi-level meshing allows the user to control the mesh sizing near the surfaces of CAD
objects without filling the entire non-conformal region with small elements. It is also known
as a hanging node mesh where a cell edge is split into two smaller edges as the mesh
gets closer to the surface. Thus each face is split into four smaller faces, and each cell into
eight smaller cells.
Note:
In Figure 31.7: Non-conformal Mesh Settings for FANS_CAD.1 Assembly (p. 751), the max
sizes in all three directions are the largest elements. The levels value set per object is the
number of times that element size will be split in half. For example, with 4 mm being the
largest element, 2 levels would correspond to a refinement of 4/2 = 2 mm for the first split
and 2/2 = 1 mm for the smallest element on that object.
Generating the Mesh
Figure 31.7: Non-conformal Mesh Settings for FANS_CAD.1 Assembly
MRF Tutorial
Figure 31.8: “Edit Levels” Settings for FANS_CAD.1 Assembly
• You are now ready to generate the mesh. Go back to the global settings and click on the Generate
button near the top of the pop-up window.
31.6. Examine the Mesh

• Display the surface mesh on the rotors by selecting them in the Model tree and going to the Display
tab of the Mesh panel. Here, select Display mesh, Surface, Wire and Solid fill (object) as options.
This will show the mesh on the surface of the fan rotor as a colored surface with lines showing the
individual elements as seen in Figure 31.9: Surface Mesh of Fan Rotors (p. 753).
Note:
It is especially important to check the surface meshes of CAD objects. If too large of an
element is being used near the surface, you may see bad elements protruding away from
or into the surface.
Examine the Mesh
Figure 31.9: Surface Mesh of Fan Rotors
• Next, create a plane cut of the mesh through the center of one of the fan rotors on the z axis. The
mesh display should look similar to Figure 31.10: Mesh Display - Cut Plane Through Rotor Center (p. 753)
(Switch off the previous surface display).
Note:
To do this properly, press Shift-x to look at the x axis, select the Cut plane option in the
Display tab under meshing, click on the drop down menu next to Set position, select
Vertical - screen select and click on the center of either fan hub. This will draw a vertical
line through the selected point. Press Shift-z to look at the plane through that line.
Figure 31.10: Mesh Display - Cut Plane Through Rotor Center
• Save the project.
MRF Tutorial
31.7. Solution Settings for MRF Fan Model

• When running a MRF model, the zero equation turbulence model will not suffice as it does not
properly capture the swirl effects of the rotor blades. It is recommended that the Realizable two
equation turbulence model be used.
• Go to Problem setup Basic Parameters and under Flow regime change the turbulence model
in the drop down menu to Realizable two equation as shown in Figure 31.11: Modify Choice for
Turbulence Model (p. 754).
Figure 31.11: Modify Choice for Turbulence Model
• Go to Solution settings Basic settings under the Model tree and set the Number of iterations
to 1000 (adequate for this model).
Solution Settings for MRF Fan Model
• Also, set the flow convergence criteria to 1e-5 and input the changes as shown in Figure 31.12: Basic
Solution Settings (p. 755).
Note:
When using MRF, the solver typically needs a larger number of iterations to completely
converge. When running the initial solution it is recommended that you set the number
of iterations to something on the order of 2000 or more to see where the convergence
finally occurs. You can lower the number of iterations in subsequent solutions with the
use of solution restart. It is also recommended to lower the convergence criteria to ensure
this convergence.
Figure 31.12: Basic Solution Settings
Point Monitors
• When running any simulation you should also include a few temperature and a few velocity monitor
points to ensure that there is complete convergence. In a steady state problem, you can have greater
confidence in the solution convergence, when the monitor values do not change for an extended
number of iterations.
• In an MRF problem, there should be multiple velocity point monitors between different blades and
located in the fluid. To do this, go the tree, right click the Points branch and select the Create at
location option.
• An easy method of creating such points is to first create a plane cut display of the mesh, as shown
in Figure 31.13: Easy Method to Snap Point Monitors to the Mesh Display (p. 756). Specify the monitor
point name and variable in the Create point panel. Finally use the Nearest option to snap the point
MRF Tutorial
to a grid location. The location of point monitors used in this tutorial are presented in
Table 31.2: Location of Point Monitors (p. 756).
Table 31.2: Location of Point Monitors
Point Monitor Location (X, Y, Z) mm Monitor

a 163.3, 159.0, 62.41 Velocity
c 172.7, 133.04, 93.6 Velocity
d 163.3, 133.04, 110 Velocity
mon_pt_1 172.7, 137.9, 135.3 Velocity
mon_pt_2 -232.6, 105.1, 98.5 Temperature
Solve the Model
• Click on in the shortcuts toolbar to bring up the Solve panel. Click on the Start solution button
to run the computations.
• If the model is set up properly as per the instructions, then the residual plots and the monitor plots
should look like Figure 31.14: Residuals Plot (p. 757).-Figure 31.16: Velocity Monitors (p. 758)
Figure 31.13: Easy Method to Snap Point Monitors to the Mesh Display
Solution Settings for MRF Fan Model
Figure 31.14: Residuals Plot
MRF Tutorial
Figure 31.15: Temperature Monitors
Figure 31.16: Velocity Monitors
31.8. Post-processing the Results
• Create an object face with the shortcut. Select all of the solid objects (blocks) other than those
in the fan assembly and select Show contours. Click on the Parameters button, leave the default
Post-processing the Results
contours of Temperature, and change the color levels to Calculated This object. The temperature
contour should look similar to Figure 31.17: Surface Temperature Contours (p. 759).
• Deactivate the temperature object face (right click and click on Active) from the Post node on the
Model tree.
• Create a plane cut with the shortcut and leave it at the default z plane through center location.
Select Contours of speed and set the color levels to be specified from 0 to 3 (velocities higher than
3 m/s will show up as red). The MRF speed contour display should look similar to Figure 31.18: Contour
of Speed at Center of Z with MRF (p. 759).
Figure 31.17: Surface Temperature Contours
Figure 31.18: Contour of Speed at Center of Z with MRF
MRF Tutorial
31.9. BONUS SECTION: Comparing MRF to 3D Icepak Fans

• Deactivate the “FANS_CAD.1” assembly and activate the “FANS_ICE3D” assembly.
• Go to Solution settings Basic settings and change the flow criteria to 1e-4.
• Go to the Solve panel and make sure that the Solution ID is different than the once used for the
MRF run. It will take much less time to run this model. You can terminate the model once the residuals
and monitor points all level off.
• Create the same speed contour as you did in the MRF run. The contour should resemble Fig-
ure 31.19: Contour of Speed at Center of Z with Icepak 3D Fan Object (p. 760). Compare this flow
pattern to Figure 31.18: Contour of Speed at Center of Z with MRF (p. 759).
Figure 31.19: Contour of Speed at Center of Z with Icepak 3D Fan Object
Chapter 32: Modeling an Airborne Electronics System
at Altitude
32.1. Introduction
There are numerous methods for cooling electronics systems and the choice of technique is generally
a function of the design, application, reliability requirements and power dissipation. For avionic elec-
tronics, one common approach is to use ambient or chilled air ducted over the sealed chassis of the
system in a cold wall. Heat from the components conducts through the PCB to the card guides that
are clamped to the chassis and removed via the cold wall.
This technique also removes any risk to the actual electronics arising from dust, moisture etc… in the
air flow, and thus increases the operating reliability.
Operating conditions of such equipment vary considerably due to the density variation of air from sea
level to cruising altitude. As the altitude increases, the density decreases, and consequently the mass
flow rates of the fan(s) are also reduced.
In this exercise a cold-wall cooled avionics unit will be modeled and the cooling efficiency evaluated
at both sea level and altitude.
Modeling an Airborne Electronics System at Altitude
This exercise assumes you have had already created some models in Icepak, and in particular have ex-
perience in meshing assemblies separately and also in setting up parametric simulations.
Note:
32.2. Opening the Project

Unpack and load the model called avionics_box.tzr.
Note:
The file avionics_box.tzr can be found on the Ansys Help Site. The procedure to
2. Download the altitude.zip file here.
3. Unzip the altitude.zip file you have downloaded to your working directory.
Adding the Fins
This is the basic cold wall geometry with two parametric runs defined. The first assumes a uniform
loading of 30 W per PCB, giving a total dissipation of 450 W for the cards. This is applied uniformly to
the card edges on both sides of the chassis.
An additional 30 W is applied to the front of the unit opposite the fan to represent any additional load
from additional equipment. The total power can be viewed in the Power and temperature limit setup
panel as shown below.
Figure 32.1: Total Power
Heat can only be conducted out of the unit, so the interior air is not modeled, and replaced by a hollow
block. Recall that within a hollow block no equations are solved, and no mesh is generated, so this
methodology reduces the problem down to a worst case scenario.
Next, you need to add two heat sinks to represent the finned cold walls on the sides of the unit.
32.3. Adding the Fins

The easiest way to add the fins is to generate two heat sinks, one for each of the cold wall ducts. Create
the heat sink objects using the information in the figures below. Also name the objects as in the figures
shown below. Note that the first two figures refer to heat_sink_minx while the second two figures
refer to heat_sink_maxx.
Figure 32.2: Object Geometry Edit Panel for heat_sink_minx
Adding the Fins
Figure 32.3: Object Properties Edit Panel for heat_sink_minx
Figure 32.4: Object Geometry Edit Panel for heat_sink_maxx
Adding the Fins
Figure 32.5: Object Properties Edit Panel for heat_sink_maxx
Create an assembly for each heat sink and choose to mesh each assembly separately and apply appro-
priate slack values. Slack values are displayed in Figure 32.6: Heat Sink Assembly Slack Values (p. 768).
Note:
Rename your assemblies to match the heat sinks’ names as shown above.
Figure 32.6: Heat Sink Assembly Slack Values
Tip:
You could have also made the second heat sink by copying the first and then using the
alignment tools to re-position it.
32.4. Modeling the effects of Altitudes

In the Basic parameters panel, click the Defaults tab. Select Air as the Default fluid.
Modeling the effects of Altitudes
Figure 32.7: Default Fluid
Go to the Advanced tab. Select the Altitude check box and ensure that the Update fan curves check
box is also selected. Enter $Elevation for the Altitude field. This creates a variable for altitude that
you will soon specify. Change the units to m. The Basic parameters panel should resemble that of
Figure 32.8: The Advanced Tab of the Basic parameters Panel (p. 770).
Figure 32.8: The Advanced Tab of the Basic parameters Panel
The Param value panel will appear upon opening the Parameters and optimization panel. Enter
10000 in the text box. This assigns an initial value of 10 kilometers for the variable Elevation.
Select the Design variables tab and then the Elevation node in the Parameters and optimization
panel. Next to Discrete values, type 0, separated by a space before 10000 as shown in Figure 32.9: As-
signing Variable for Altitude (p. 771).
Figure 32.9: Assigning Variable for Altitude
Now edit the fan object (fan.1) in the model. At altitude the inlet temperature will be very different
from the same flow rate at sea level. Assign a parameter for the inlet temperature as shown in the Fans
panel of Figure 32.10: Assigning Parameters for Inlet Temperature (p. 772). Initialize the variable Flow_T
with a value of -5 after updating the fan object. The temperature parameter should take the values 20
and -5 ºC as shown in the Parameters and optimization panel of Figure 32.10: Assigning Parameters
for Inlet Temperature (p. 772). Apply these settings, and reset the trials. Check that the correct combin-
ation of parameters for sea level, and 10 Km for elevation have been assigned.
Figure 32.10: Assigning Parameters for Inlet Temperature
In the Functions tab of the Parameters and optimization panel, create three functions, one to report
the global maximum temperature and the other two to calculate the pressure drop across each of the
heat sinks. Figure 32.11: Primary Functions (p. 773) and Table 32.1: Functions (p. 773) show the functions’
names and specifications.
Figure 32.11: Primary Functions
Table 32.1: Functions
Function Function Value Object, Variable, Direction

name type
maxTemp Global value Global maximum
temperature
DP-1 Difference object heat_sink_minx, Pressure, Low Z - High
Z
DP-2 Difference object heat_sink_maxx, Pressure, Low Z - High
Z
Click Run to run the trials and then analyze the two simulations to compare results. Generate some
particle tracks from the fan through the system and display the object faces of the two heat sinks.
Create a summary report for both runs for the temperatures of the sources. Combine these into an
HTML report.
Figure 32.12: Parametric Trials
Create particle traces with the shortcut. In the Object face panel that appears, select object
fan.1 and select the Show particle traces option. Click the Parameters button and leave the default
settings. Change the color levels to Calculated This object. The particle traces should look similar to
Figure 32.13: Particle Traces (p. 774).
Figure 32.13: Particle Traces
Deactivate the temperature object face (right-click face.1 in the Model manager window and deselect
Active).
Create an object face to display temperature contours on the heat sink objects. The object face should
look similar to those in Figure 32.14: Temperature Contours on heat_sink_minx and
heat_sink_maxx (p. 775).
Summary
Figure 32.14: Temperature Contours on heat_sink_minx and heat_sink_maxx
32.5. Summary
In this tutorial, you learned how to model the effects of altitude in Ansys Icepak by using the Parameters
and optimization panel to create parametric variables.
Chapter 33: Maxwell and Ansys Icepak Coupling
Tutorial
33.1. Introduction
This tutorial demonstrates how heat loss data can be transferred between Maxwell and Ansys Icepak
in Ansys Workbench. This tutorial involves an eddy current solver of Maxwell to calculate heat losses
which are then applied to Ansys Icepak to simulate natural convection.
• Create a Maxwell and Ansys Icepak coupling analysis in Ansys Workbench.
• Transfer heat loss data bi-directionally between Maxwell and Ansys Icepak using the Feedback Iterator.
Note:
33.2. Prerequisites
This tutorial assumes that you have little experience with Ansys Workbench and so each step will be
explicitly described. A Maxwell license is needed to perform this tutorial.

A simple model is used in this tutorial to demonstrate multiphysics coupling. Heat flow is calculated
on the Stock object in Maxwell and is transferred to Ansys Icepak.

Note:
Maxwell and Ansys Icepak Coupling Tutorial

You will import an existing Maxwell project into Workbench. To import a Maxwell file,
• Specify a name for your project (that is, maxwell2wb) and save the Workbench project file. File>Save
As...
• Select the menu item File>Import in Workbench.
• Change the file type to Ansys Electronics Desktop Project File (*.aedt) and browse to the location of
the tutorial input file.
• Select the file Maxwell_Icepak_Coupling.aedt and open it.
Note:
The file Maxwell_Icepak_Coupling.aedt can be found on the Ansys Help Site. The
procedure to download this file is described below.
2. Download the maxwell.zip file here.
3. Unzip the maxwell.zip file you have downloaded to your working directory.
• Double-click the Setup cell of the Maxwell3DDesign1 system to launch Maxwell.
In this step you will set the conductivity of the aluminum plate as function of temperature. This will
enable you to get the temperature from Icepak and recalculate the losses based on temperature de-
pendent properties. To set temperature dependent properties,
• Select the Stock object from the history tree, right-click and select Assign Material.
Figure 33.1: Assign Material for Stock Object
• In the Select Definition panel, select View/Edit Materials....
Figure 33.2: Select Definition Panel
• In the View/Edit Material panel,
– Enable Thermal Modifier.
– Go to the Thermal Modifier column for bulk conductivity and select Edit from the drop-down
menu.
– In the Edit Thermal Modifier panel,
→ Set modifier as: if (Temp <=22, 1, 1/(1+0.0039*(Temp-22)))
→ Click OK.
Figure 33.3: Edit Thermal Modifier
– Click OK to close the View/Edit Material and the Select Definition panels.
In this step, you will enable the temperature feedback.
• From the Maxwell 3D menu, select Set Object Temperature.
• In the Temperature of Objects panel, enable Include Temperature Dependence and Enable
Feedback.
• Click OK.
Figure 33.4: Temperature of Objects Panel
Verify Maxwell settings.
• Expand the Project Manager tree and Analysis.
• Double-click on Setup1 to display the Solve Setup panel.
• In the Solve Setup panel, ensure the following settings are defined:
– General tab, Percent Error: 0.1
– Convergence tab, Refinement Per Pass: 50%
– Solver tab, Adaptive Frequency: 200Hz
– Click OK.
Note:
After entering the specifications, the Geometry and Setup cells in the Maxwell system
should appear as follows:
Figure 33.5: Maxwell 3D system
Validate the model.
• From the Maxwell 3D menu, select Validation Check.
Click the Close button.
Note:
To view any errors or warning messages, use the message manager.
To start the solution process:
• From the Maxwell 3D menu, select Analyze All.
Calculate Ohmic losses in Stock.
• From the Maxwell 3D menu, select Fields > Calculator.
– Select Input > Quantity > OhmicLoss
– Select Input > Geometry > Volume > Stock
– Select Scalar > integrate
– Select Output > Eval
• The Ohmic losses in Stock volume are around 8.7 Watts.
• Click Done to exit.
Close Maxwell.
• From the File menu, select Close Desktop.
Note:
After solving, the Maxwell3DDesign1 system should have green check mark in the
Solution cell. If not, select Update from the context menu of the Solution cell.
Save the project.
• Return to Workbench project window.
• Select the menu item File>Save.
In the project schematic, drag and drop a Geometry system on top of the Maxwell 3D Geometry cell
(A2). Right-click the Geometry cell (B2) and select Update. Right-click the Geometry cell and select Edit
Geometry in DesignModeler to launch DesignModeler. Click Generate to create the objects.
Suppress Geometry
• On the tree outline, right-click on the coil_Section1 object and click Suppress Body.
• Repeat this same procedure with the dummy object.
Figure 33.6: Suppress Bodies
Simplify Geometry
• Set the geometry selection filter to bodies and select the Coil object. Go to the Tools menu. Select
Electronics> Simplify. Note that Simplify1 shows up on the tree outline and the Details view is
populated with the simplified form. Go to the Details view.
• Click Apply across from the Select Bodies field.
• Change the Simplification Type to Level 3 (CAD Object). Ensure Selected Bodies is selected for
the Selection Filter and choose Fine for Facet Quality.
Figure 33.7: Simplify1 – Coil Object
• Click Generate.
Note:
The coil object has now been converted into a simple shape and hence is automatically
recognized as a CAD block object in Icepak.
• Next, simplify the Stock object using Level 2 (Polygon fit) for the Simplification Type. See the figure
below.
Figure 33.8: Simplify2 – Stock Object
Save the project in Ansys DesignModeler and close the application.
Drag and drop an Icepak system on top of the Geometry cell to transfer the geometry. Click on the
Maxwell 3D Solution cell (A4) and drag and drop it onto the Icepak Setup cell (C2) as shown below.
Right-click on the Maxwell3DDesign1 Solution cell (A4) and select Update.
Double-click the Icepak Setup cell (C2) to open Icepak. You will see that the geometry has been imported.
Figure 33.9: Imported Geometry in Icepak
• Resize the cabinet as shown in the figure below.
Figure 33.10: Resize Cabinet
• In the Cabinet panel, click the Properties tab and assign Openings. Change the Min z and Max z
Wall type to Opening.
Figure 33.11: Cabinet Properties
• Change the material of Coil object.
– In the Properties tab, specify the Solid material as Copper (Cu-Pure).
Figure 33.12: Coil Material
The material for the Stock object is Aluminum; therefore keep the selection of default for the Stock
object.

Open the Mesh control panel and enter the specifications as shown below, ensuring Multi-level
meshing is used. Keep the default settings for all other inputs.
Click Generate to mesh the model. Visualize the mesh at plane cuts and surface displays from the
Display tab.

• Go to Problem setup Basic parameters. In the General setup tab, select On under Radiation.
1. Select Discrete ordinates radation model and click Options.
2. Under Iteration parameters, enter 5 for Flow iterations per radiation iteration and click
Accept.
• Enable the Gravity vector and make sure that gravity in the z-direction is -9.80665 m/ . Set the y-
direction Gravity vector to 0.
• On the Transient setup tab under Solution initialization, enter 0.01 m/s for Z velocity.
• Under Solution settings Basic settings, enter 200 for the Number of iterations.
• Click Accept and close the Basic settings panel.
• Go to Solution settings Advanced settings.
1. Under Under-relaxation, enter 0.7 for Pressure.
2. Under Under-relaxation, enter 0.3 for Momentum.
3. Make sure the Precision for the solver is Double.
4. Click Accept in the Advanced solver setup panel.
• Go to the File menu, select EM mapping and Volumetric heat losses.
– Select Stock_0, Stock_1, and Stock_2.
– Retain the default Solution ID and select the Frequency (Hz) as displayed in Figure 33.14: Volu-
metric heat losses (p. 798).
Figure 33.14: Volumetric heat losses
– Click Accept to close the panel.

File Save project

1. Go to Solve → Run solution to display the Solve panel.
2. Keep the default settings in the Solve panel.

1. After calculating a solution in Ansys Icepak, a green check mark will be displayed in the Icepak
Solution cell in the Project Schematic. The green check mark indicates that all data is up to date.
2. In Icepak, go to the Solve menu and select Define report. In the Define summary report panel,
keep the default specifications. Select New and select the Stock objects in the Objects drop-down
list. Click Accept. For the Value, select Heat flow. Click Write to display the Report summary data
panel shown in Figure 33.16: Report summary data Panel (p. 800). Note that the Heat flow is 8.7 Watts.
Figure 33.15: Define summary report Panel
3. Click Done to close the Report summary data panel and Close to exit the Define summary report
panel.
33.11. Step 8: Iterate in Workbench

1. In Icepak, select File > EM Mapping > Volumetric Heat Loss to open the Volumetric Heat Losses
panel. Select Temperature Feedback and click Accept.
Step 8: Iterate in Workbench
2. From the Solve menu, select Run Solution to open the Solve panel. Rename the Solution ID as
"Feedback_Iterator_Run" and click Dismiss.
3. From the File menu, select Save project.
4. From the File menu, select Close Icepak.
5. In Workbench, select a Feedback Iterator component and drag it onto the Maxwell project's Setup
cell.
6. Right-click the Feedback Iterator cell (D2) select Properties and edit the following properties:
• Max Iterations: 4
• Target Delta Temperature %: 5
7. Right-click the Feedback Iterator cell (D2) select Single Iteration Update. Wait until the Icepak
solution has completed.
Step 9: Examine Feedback Iterator Run Results
8. In Icepak, click Done to close the solution residuals panel.
9. From the File menu, click Close Icepak.
10. After the single iteration update is complete, right-click the Feedback Iterator cell (D2) and select
Update.
33.12. Step 9: Examine Feedback Iterator Run Results

After the iterations complete, examine the Ohmic loss in Maxwell and the Heat flow in Icepak.
1. In Workbench, double-click the Maxwell3DDesign1 Solution cell to launch Maxwell.
2. From the Maxwell 3D menu, select Fields > Calculator.
• Select Input > Quantity > OhmicLoss
• Select Input > Geometry > Volume > Stock
• Select Scalar > integrate
• Select Output > Eval
3. The Ohmic losses in Stock volume are around 8.8 Watts.
Step 9: Examine Feedback Iterator Run Results
4. Click Done to exit.
5. From the File menu, select Close Desktop.
6. In Icepak, go to the Solve menu and select Define report. In the Define summary report panel,
click Write. The Heat flow for the stock objects is around 8.8 Watts.

In this tutorial, heat losses are transferred from Maxwell to Ansys Icepak using Ansys Workbench. Using
one-way couping, the heat flow indicated in the Report summary data panel is around 8.4 for the
Stock which is the same value calculated in Maxwell using the Fields calculator. Using the Feedback
Iterator to create bi-directional iterative coupling, Maxwell and Icepak report an increase in heat flow.
Icepak reports a heat flow of around 8.5 for the Stock which is the same value calculated in Maxwell
using the Fields calculator.
Chapter 34: Icepak – HFSS Coupling
34.1. Introduction
This tutorial demonstrates how to model an Ansys Icepak– HFSS workflow.
• Perform an HFSS analysis.
• Understand the volumetric and surface losses on a hybrid ring plate.
• Compare losses in HFSS and Ansys Icepak to validate the data transfer.
Note:
34.2. Prerequisites
This tutorial assumes that you have basic familiarity with the setup and solution of HFSS and Ansys
Icepak simulation.

The hybrid ring plate is considered for understanding the effect of volumetric and surface losses on the
temperature prediction of the ring.
Icepak – HFSS Coupling

In Workbench, go to File menu and select Restore Archive to open the project, icepak-hfss-tutorial.wbpz.
The procedure to download this file is described below.
2. Download the hfss.zip file here.
3. Unzip the hfss.zip file you have downloaded to your working directory.

1. An HFSS project is present in the schematic. Perform a right mouse click on the Geometry cell (A2)
and go to Transfer Data To New > Geometry. The geometry is directly shared from HFSS Geometry
using a DM connection.
2. Double-click the Geometry cell (A2) to open HFSS. Observe the geometry which opens in HFSS.
3. Minimize HFSS, right-click on the Geometry cell (B2) and select Refresh.
4. Right-click the Geometry cell (B2) and select Edit Geometry in DesignModeler to open Design-
Modeler as you need to edit the geometry first before exporting into Ansys Icepak.
a. Click Generate to display the model.
b. Expand the node containing the parts and bodies. Suppress bodies Port, Port_1, Port_2 and
Port_3.
c. Edit the geometry in DesignModeler using the Electronics option in the Tools menu.
• Select Simplify and choose Level 3 simplification for Outer1.
• Make sure to select Very Fine for the facet quality.
• Click Generate.
• Select Simplify and choose Level 2 simplification for the Substrate.
• Click Generate.
• Close DesignModeler and return to Ansys Workbench.
Note:
The Electronics menu is shown only if the DesignModeler option Enable Electronics
Options is turned on.
5. Drag and drop an Ansys Icepak template onto the project schematic on top of the Geometry cell
(B2) to transfer the geometry into Ansys Icepak. Connect the HFSS Solution cell to the Icepak Setup
cell.
6. Right-click the HFSS Solution cell (A4) and select Update to run the HFSS analysis.
7. Right click on the Setup cell (C2) and select Edit to launch Ansys Icepak.
a. Resize the cabinet using the following dimensions in meters.
Table 34.1: Cabinet Geometry
xS -0.04 xE 0.04
yS -0.03 yE 0.03
zS -0.003 zE 0.003
b. Create openings on the sides of the Cabinet for the flow inlet (Min x) and outlet (Max x). Specify
X velocity of 0.1 m/s for opening in min-x direction.

1. Update the mesh priority so Outer1 has higher priority than the Substrate. The Edit priorities option
can be found under the Model menu.
2. In the Mesh control panel, specify Mesher HD for this model as it contains CAD objects.
3. Select Set uniform mesh params under the Global tab.
4. Select Allow multi-level meshing under the Multi-level tab.
5. Click the Generate button to generate the mesh.

Before starting the solver, you will first check that the proper flow regime is being modeled.
1. Go to Problem setup → Basic parameters in the Model manager window.
a. In the General setup tab, make sure that both flow and the temperature fields are switched on.
b. Select Laminar for the Flow regime and turn Off the Radiation.
c. Click Accept to close the panel.
2. Go to Solution settings → Basic settings and Solution settings → Advanced settings

in the Model manager window and verify that the following values are set for each variable:
Basic settings
No. of iterations = 500
Flow = 0.001
Energy = 1e-7
Advanced settings
Discretization scheme (Momentum and Temperature) = First order
Precision = Double
34.8. Step 5: Volume/Surface Mapping

1. Go to File → EM Mapping →Volumetric heat losses.
2. Select Outer1 and Substrate for which losses needs to be applied.
3. Set the Frequency (Hz) as displayed in the image below.
4. Click Accept.

File → Save project
Note:

1. Solve the Ansys Icepak model by updating in Ansys Workbench or by clicking Solve in Ansys Icepak.
Note:
Solution completes approximately after 60 iterations.

Create a summary report for heat-flow of substrate in Ansys Icepak.
1. Select Report → Summary Report
a. Click New and select Substrate in Objects box. (Dielectric losses are predominant in Substrate).
b. Select Heat Flow for Value.
2. Click Write to obtain the heat-flow.
Ansys Icepak reports 0.2408 Watts
Evaluate volume loss for substrate in HFSS.
1. Open the HFSS application and select the HFSS model. From the menubar, HFSS →Fields →Calcu-
lator
a. UnderInput, click on Quantity and select VolumeLossDensity . Then click OK.
b. Under Input, click on Geometry and select Volume and then Substrate. Then click OK.
c. Select Scalar > integrate.
d. Click on Eval to report the total volume loss density of substrate.
2. HFSS reports 0.24353 Watts.
Note:
Heat flow value from HFSS can also be obtained from uns_out file.
Evaluate surface/conductor losses in Ansys Icepak.
2. Un-check the bodies selection from Volumetric heat losses panel.
3. Click Accept.
4. Select File>EM Mapping>Surface heat losses option.
5. Select body Outer1 for which losses needs to be applied.
Note:
Outer1 is selected as conductor losses are predominant in this body.
6. Click Accept.
7. Retain all other settings in the solve panel.
8. Enter new Solution ID and solve the Ansys Icepak model.
Create a summary report for heat-flow from the openings of the cabinet.
1. Heat flow from cabinet boundaries represent surface heat loss as no other device is generating heat.
Select Report →Summary Report
1. Select minx and maxx openings in the objects list.
2. Select Heat Flow for Value.
Click Write to obtain the heat flow.
Ansys Icepak reports 0.712 Watts
Evaluate surface loss for Outer1 surface in HFSS.
Select HFSS→ Fields→Calculator
1. Under Input, click Quantity and select SurfaceLossDensity. Then click OK.
2. Under Input, click Geometry and select Surface and then Outer1. Then click OK.
3. Select Scalar > integrate.
4. Click on Eval to report the total surface loss density of substrate.
HFSS reports 0.712 Watts.
Note:
Evaluate volumetric and surface losses in Ansys Icepak
2. Select Volumetric heat losses option.
a. Select the Substrate only to solve for which losses needs to be applied.
3. Click Accept.
4. Retain all other settings in the solve panel.
5. Enter new Solution ID and solve the Ansys Icepak model.
Comparison of Total Loss (Volumetric and Surface)
1. Create a summary report for heat-flow from the openings of the cabinet.
• Heat flow from cabinet boundaries represent total heat loss as no other device is generating heat.
2. Select Report →Summary Report
a. Select minx and maxx openings in the objects list.
b. Select Heat Flow in Values.
3. Click write to obtain the heat-flow.
4. Ansys Icepak reports 0.95563 Watts.
5. Evaluate surface loss for Outer1 surface in HFSS.
• HFSS reports 0.712 Watts.
6. Evaluate volume loss for Substrate in HFSS.
• HFSS reports 0.24353 Watts
Step 9: Summary
7. Summation of above losses equals to 0.95 Watts.
Note:

In this tutorial, volumetric and surface losses are transferred from HFSS to Ansys Icepak using the Ansys
Workbench connection. A validation/comparison is performed between the data in HFSS with Ansys
Icepak.
Chapter 35: SIwave - Icepak Coupling
35.1. Introduction
This tutorial demonstrates how to perform an Ansys SIwave - Ansys Icepak workflow. SIwave is used to
compute Joule heating in a printed circuit board. The SIwave heat load is imported in Icepak to solve
for the temperature field using heat transfer coefficient boundary conditions. We iterate among the
two solvers until power and temperature fields converge.
• Perform two-way coupling between SIwave and Icepak and examine results.
• Note:
35.2. Prerequisites
This tutorial assumes that you have basic familiarity with the setup and solution of SIwave and Icepak
simulations.

The board layout is used for performing a DC IR drop computation.

1. Open a new session of Ansys SIwave. When SIWave starts, the Welcome to Ansys SIwave panel
opens.
2. Select Open Project from the Start panel. Select DCIR.siw from the file selection panel and click
Open to load the project.
This file is located on the Ansys Help Site. The procedure to download this file is described below.
2. Download the siwave.zip file here.
SIwave - Icepak Coupling
3. Unzip the siwave.zip file you have downloaded to your working directory.
35.5. Step 2: Run an SIwave Simulation

1. From the Common Functions, click the SIwave Workflow Wizard button.
Figure 35.1: SIwave Workflow Wizard Button
The SIwave Workflow Wizard is displayed.
Figure 35.2: SIwave Workflow Wizard
2. Optional: click Verify Stackup. The Layer Stack-up Editor is displayed.
Step 2: Run an SIwave Simulation
a. Verify that all layers imported correctly.
Note:
When coupling with Ansys Icepak, it is recommended to delete any non-metal

and dielectric layers.
b. Click OK to return to the SIwave Workflow Wizard.
Figure 35.3: Layer Stack-up Editor
3. Optional: click Verify Padstacks. The Padstack Editor is displayed.
a. Via Plating determines the amount of conductor plating inside of a via. Select a padstack
and use the slider bar to change the Ratio percentage. SIwave defaults all via plating to
100% for all padstacks. Alternatively, you can select Absolute to specify wall thickness.
b. Click Cancel to discard the changes and return to the SIwave Workflow Wizard.
Figure 35.4: Padstack Editor
4. Optional: click Verify Circuit Element Parameters. The Circuit Element Properties panel is displayed.
Figure 35.5: Circuit Element Properties Panel
Note:
Inductors and Resistors are important for DC operation.
a. On the Inductors and Resistors tabs, verify that they have been imported properly.
b. On the Resistors tab, select the first resistor named R1 and click Modify Properties. The Set
Resistor Parameters panel is displayed.
c. In the Set Resistor Parameters panel, you can change the Name or the associated Part Number.
Figure 35.6: Circuit Element Properties Panel
d. Click Cancel to close the Set Resistor Parameters panel and click Cancel to return to the SIwave
Workflow Wizard.
5. Optional: click Verify Power/Ground Net Classification. The Power/Ground Net Classification
panel is displayed.
Note:
SIwave automatically classifies any net defined with polygons or shapes as Power/Ground
Nets. SIwave does not automatically classify nets with only traces and padstacks as
Power/Ground Nets.
a. In the Power/Ground Net Classification panel, you can move nets in and out of the classification
using the up and down arrow buttons.
b. Click Auto Identify to return the classification to the default and click OK to return to the SIwave
Workflow Wizard.
Figure 35.7: Power/Ground Net Classification Panel
6. In the SIwave Workflow Wizard, click Configure DC IR Drop Analysis. The DC IR Configuration
panel is displayed.
Figure 35.8: DC IR Configuration Panel
a. Select the check box next to net V3P3_S0. Any active devices connected to this net are displayed.
b. Deselect Hide RLC components to see passive devices and select it again to hide them.
c. Verify that the current and voltage sources are set as shown in Figure 35.9: Current and Voltage
Sources (p. 829).
Figure 35.9: Current and Voltage Sources
d. Click Save to save a flow configuration file (.fcf ). Choose a file name and save it in your working
directory. This can be loaded for subsequent simulations.
e. Click Configure Simulation to apply pin groups and excitations to the design.
f. Click Validate. The Launch Validation Check panel is displayed.
Figure 35.10: Launch Validation Check Panel
Note:
The validation check analyzes the entire setup to ensure it is ready for simulation.
g. Use the up arrow button to increase the Number of cores to use. Use as many cores as are
available.
h. Click OK to start the validation check. After the validation check is complete, the Validation
Check Results panel is displayed.
Figure 35.11: Validation Check Results Panel
Note:
If there are certain geometry problems, such as disjointed nets or overlapping vias,
you can resolve them by selecting the Auto Fix check box and clicking OK.
i. Click OK to close the Validation Check Results panel and return to the DC IR Configuration
panel.
Figure 35.12: DC IR Configuration Panel
j. Click Simulate. The Compute DC Current and Voltage Distribution panel is displayed.
Figure 35.13: Compute DC Current and Voltage Distribution
k. Ensure that the Compute DC Current and Voltage Distribution options are set as they are in
Figure 35.13: Compute DC Current and Voltage Distribution (p. 832).
l. Click Other solver options. The SIwave Options panel is displayed.
Figure 35.14: SIwave Options Panel - DC Tab
m. On the DC tab, move the slider bar to the different options and click on the DC Advanced tab
to view which settings are affected.
n. When you are finished, use the slider bar to select Balanced.
o. On the DC Advanced tab, note that we are meshing vias and performing adaptive mesh refine-
ment for planes and traces.
Figure 35.15: SIwave Options Panel - DC Advanced Tab
Note:
For a DC simulation, High Performance Computing can distribute the solver across
multiple cores. A High Performance Computing license is required to use multiple
cores.
p. On the Multiprocessing tab, click the up arrow to increase the Number of cores to use.
q. Ensure that the Multiprocessing options are set as they are in Figure 35.16: SIwave Options
Panel - Multiprocessing Tab (p. 835).
Figure 35.16: SIwave Options Panel - Multiprocessing Tab
r. Click OK to close the SIwave Options panel.
s. On the Compute DC Current and Voltage Distribution panel, click Launch.
Figure 35.17: Compute DC Current and Voltage Distribution
t. The Process Monitor displays the simulation status and steps taken by the solver. Information/Er-
rors/Warnings displays any potential issues that may arise during the solution process.
Figure 35.18: Process Monitor and Information/Errors/Warnings Panels
7. From the SIwave Export tab, click ANF in... and select Generic Format. In the Save As panel, save
the .anf file as Coupling_anf.anf in your working directory.
Figure 35.19: Export ANF File in Generic Format
35.6. Step 3: Run an Icepak Simulation (Conduction Only)

1. On the SIwave Simulation tab, click Icepak.
Figure 35.20: SIwave Simulation Tab
2. In the Icepak Simulation Setup dialox box, specify a Setup Name for the simulation.
Figure 35.21: Icepak Simulation Setup Dialog Box - Simulation Setup Tab
3. For DC Sim Results, note that the initial DC IR solution is automatically selected.
Step 3: Run an Icepak Simulation (Conduction Only)
4. For DC Power Convergence, retain the default and ensure Repeat simulations until DC convergence
is enabled.
5. Under Thermal Simulation Type, select Conduction (PCB only - no components).
6. Retain the settings for Meshing Detail and Board Outline Fidelity.
7. Select Use Classic Icepak.
8. If High Performance Computing licensing is available, increase the Number of cores to use.
9. On the Thermal Environment tab, retain the settings for Forced Convection.
Figure 35.22: Icepak Simulation Setup Dialog Box - Thermal Environment Tab
Note:
Conduction-only modeling sets wall boundary conditions based on flow inputs. Inputs
can be based on forced convection (forced airflow) or natural convection (bouyancy-
based).
• Forced Convection has separte top and bottom flow rate and temperature
inputs.
• Natural Convection uses the board orientation only (gravity direction) and
ambient temperature.
Note:
As this is a conduction-only simulation, there are no components or cabinet size

settings to define.
Step 3: Run an Icepak Simulation (Conduction Only)
10. Click Launch to start the Icepak simulation. The simulation progress is displayed in the Process
Monitor.
Figure 35.23: Process Monitor
11. When the simulation loop is complete (after DC IR Sim 2), right-click on the Icepak simulation in the
Results pane (Icepak Sim 1) and select Display Temperature to show the temperature contours.
Figure 35.24: Results Pane
Figure 35.25: Temperature Contours
35.7. Step 3: Run an Icepak Simulation (Forced Convection)

1. On the SIwave Simulation tab, click Icepak.
2. In the Icepak Simulation Setup dialox box, specify a new Setup Name for the simulation, such as
Icepak Sim 1 - Convection.
Step 3: Run an Icepak Simulation (Forced Convection)
Figure 35.26: Icepak Simulation Setup Dialog Box - Simulation Setup Tab
4. For DC Power Convergence, retain the default and ensure Repeat simulations until DC convergence
is enabled.
5. Under Thermal Simulation Type, select Convection (Components optional).
6. Retain the settings for Meshing Detail and Board Outline Fidelity.
7. Select Use Classic Icepak.
8. If High Performance Computing licensing is available, increase the Number of cores to use to 4.
Figure 35.27: Icepak Simulation Setup Dialog Box - Thermal Environment Tab
10. On the Component Configuration tab, click the Heat Sink column header to deselect all check
boxes in the column. Also click the Include column header twice to deselect all check boxes in
column to match conduction-only settings.
Step 3: Run an Icepak Simulation (Forced Convection)
Figure 35.28: Icepak Simulation Setup Dialog Box - Component Configuration Tab
Note:
Component Type, Part, and Reference Designator information is displayed in the

table. Length and Width should be accurate. Verify the Height and Power Dissipa-
tion.
11. On the Icepak Cabinet Size tab, enter the padding settings under Size Relative to Board Dimension
as displayed in the image below.
Figure 35.29: Icepak Simulation Setup Dialog Box - Icepak Cabinet Size Tab
12. Click Save Settings.
13. Click Launch to start the Icepak simulation. The simulation progress is displayed in the Process
Monitor.
14. When the simulation loop is complete (after DC IR Sim 2), right-click on the Icepak simulation in the
Results pane (Icepak Sim 1 - Convection) and select Display Temperature to show the temperature
contours.
Figure 35.30: Results Pane
Step 4: Run a Single Board Setup in Icepak
Figure 35.31: Temperature Contours - Forced Convection
Note:
Temperature distribution is slightly different due to true fluid flow calculations rather
than an estimated boundary condition (as in conduction-only modeling).
35.8. Step 4: Run a Single Board Setup in Icepak

Use the Export Icepak functionality to run a full system loop in Ansys SIwave and Ansys Icepak, starting
with a single board setup.
1. In your working directory, create a new folder named IceSingle.
2. Copy and paste the DCIR_solved.siw file and DCIR_solved.siwaveresults folder into
the IceSingle folder.
Note:
The loop from Icepak creates separate files that should be run in their own location.
If you choose to re-run the DCIR simulation, re-run in a new folder.
3. In SIwave, open the DCIR_solved.siw project.
Important:
At this point, we are no longer using the DCIR.siw project. Ensure you are working
with the DCIR_solved.siw project.
4. On the Export tab, click Icepak.
Figure 35.32: SIwave Export Tab
5. In the Icepak Export dialox box, specify the Project Directory as SingleIceRun within the
IceSingle.
Figure 35.33: Icepak Export Dialog Box - Simulation Setup Tab
7. Under Thermal Simulation Type, select Convection (Components optional).
8. Retain the defaults for Meshing Detail and Board Outline Fidelity.
9. Set the Number of cores to use as 2.
Figure 35.34: Icepak Export Dialog Box - Thermal Environment Tab
11. On the Component Configuration tab, click the Include column header to deselect all check boxes
in the column. Also ensure the check boxes in the Heat Sink column are deselected.
12. For the following components, select the Include check box and define the Height and Power
Dissipation (W) settings as shown.
Figure 35.35: Components To Include and Modify
13. On the Icepak Cabinet Size tab, enter the padding settings under Size Relative to Board Dimension
as displayed in the image below.
Figure 35.36: Icepak Export Dialog Box - Icepak Cabinet Size Tab
14. Click Save Settings and then OK. An initial Icepak project launches with base geometry, mesh and
solver settings.
15. Save the Icepak project and close Icepak.
Note:
To run the SIwave Icepak Coupling > PCB Iterator macro, Icepak must be running
in a standalone instance.
16. Open the saved project in Icepak.
17. In the Icepak Project tree, right-click on the OUTER assembly and select Expand all.
18. Delete the inlet and outlet openings. Examine the model in the graphics window.
Figure 35.37: Model in the Icepak Graphics Window
19. In the Project tree, expand Problem setup and double-click Basic Parameters to open the Basic
parameters panel.
20. Under Flow regime, select Turbulent and select Zero equation.
Figure 35.38: Basic Parameters Panel
21. In the Project tree, double-click the Cabinet to open the Cabinet panel.
22. On the Geometry tab, edit the Location information as shown in the image below.
Figure 35.39: Cabinet Panel - Geometry Tab
23. On the Properties tab, change Max X to a Grille and click Edit to open the Grille panel
Figure 35.40: Cabinet Panel - Properties Tab
24. On the Properties tab, enter a Free area ratio of 0.75 to add a pressure drop to the system.
Figure 35.41: Grille Panel - Properties Tab
25. In the Project tree, double-click the BOARD_DCIR_solved PCB object to open the Printed Circuit
Boards panel.
26. On the Properties tab under Thermal specification, click ensure SIwave profile is selected and
click Edit.
Figure 35.42: Printed Circuit Boards Panel - Properties Tab
27. In the SIwave powermap properties panel, select Apply trace transform and click Browse and
navigate to dcthermal in SingleIceRun results directory. Repeat for the other four layers and then
click Info for the first layer listed. Power locations are displayed in the graphics window, and inform-
ation is displayed in the Powermap Info panel.
Figure 35.43: Powermap Locations and Information
28. Close the Powermap Info panel and click Accept in the SIwave powermap properties.
29. Click Done to close the Printed Circuit Boards panel.
30. Click on the Fan button to create a fan, and then double-click on the fan object in the Project tree
to open the Fans panel.
31. On the Geometry tab, define the settings as shown in the following image. Note that the units are
set to mm.
Figure 35.44: Fan Panel - Geometry Tab
32. On the Properties tab, define the settings as shown in the following image. Note that the unit for
flow is set to cfm.
Figure 35.45: Fan Panel - Properties Tab
33. Click Done to save the settings and close the Fans panel.
34. In the Project tree, right-click on the fan object and select Copy.
35. In the Copy fan panel, select Translate under Operations and enter a Y offset of 45 mm.
Figure 35.46: Copy Fan Panel
36. Click Apply to close the Copy fan panel and create the copied fan object.
37. In the Project tree, use the Shift key to select both fans. Right-click and select Create > Assembly.
The new assembly appears in the Project tree.
38. Double-click the assembly to open the Assemblies panel.
39. On the Info tab, enter a Name of FANS.
40. On the Meshing tab, define the settings as shown in the following image. Note that the units are
set to mm.
Figure 35.47: Assemblies Panel - Meshing Tab
41. Click Done to save the settings and close the Assemblies panel.
42. From the Model menu, select Generate mesh to open the Mesh control panel.
43. Retain the settings created by SIwave and click Generate to create the mesh.
44. When the mesh is generated, click the Display tab and define the settings as showin in the following
image to inspect the mesh.
Figure 35.48: Mesh Control Panel - Display Tab
45. From the Orient menu, select Orient Positive Y. The mesh should be similar to that shown in the
following image.
Figure 35.49: Model Mesh
46. Disable Display mesh to hide the mesh and click Close.
47. From the Macros menu, select Modeling > SIwave Icepak Coupling > PCB Iterator.
Note:
This macro can be used for existing setups of single or multiple boards.
48. In the SIwave-Icepak Coupling Iterator for Single and Multiple PCBs panel, click New.
49. Select the BOARD_DCIR_solved PCB object and DCIR_solved SIwave project and set the Termin-
ation Convergence Criteria as shown in the image below.
Figure 35.50: SIwave-Icepak Coupling Iterator for Single and Multiple PCBs Panel
50. Click Accept to run the simulation. When the simulation is complete, the following panel appears.
Figure 35.51: Instructions Panel
51. In the Project tree, right-click Model and select Expand all to display all model objects in the
graphics window.
52. Using the Shift key to select the PCB object and four components (as shown in the image below),
right-click and select Create > Object faces > Combined.
Figure 35.52: Project Tree - Object Selection for Object Face
53. In the Object face panel, enter a Name of Temp.
54. Ensure Show contours is enabled and click Parameters.
55. In the Object face contours panel, select This object from the Calculated drop-down list.
Figure 35.53: Object Face and Object Face Contours Panels
56. Click Done in both panels to display the updated temperature values.
Figure 35.54: Object Face - Temperature Contours
57. In the Project tree under Post-processing, right-click Temp and select Active to hide the object
face.
58. From the horizontal toolbar, click the Object face button to create a new object face to display flow
data.
59. In the Object face panel, enter a Name of Flow.
60. From the Object drop-down list, select the fan items from both fan objects and click Accept (see
the following image).
61. Select Show particle traces and click Parameters.
62. In the Object face particles panel, define the settings as shown in the following image.
Figure 35.55: Object Face and Object Face Particles Panels
63. Click Animate to display the particle traces.
Figure 35.56: Object Face - Speed Particle Traces
64. From the File menu, select Pack project.
65. In the File selection panel, create a new folder named IceMult on the same level as IceSingle.
Save the project as SingleRunIce.tzr.
You have now added more system detail to a generic SIwave convection run to test real-life board
DCIR conditions for a single board.
Note:
Offset and rotation of the board in Icepak will automatically adjust to the correct
location in SIwave.
35.9. Step 5: Run a Multi-Board Setup in Icepak

1. Copy and paste the DCIR_solved.siw file and DCIR_solved.siwaveresults folder into
the new IceMult folder.
2. In Icepak from the File menu, select Unpack project.
3. In the File Selection dialog box, navigate to the IceMult folder, select the SingleRunIce.tzr,
and click Open.
4. In the Location for the unpacked project panel, enter a project name of MultRunIce and click
Unpack.
5. From the File menu, select Save project.
6. In the Project, tree, right-click the OUTER assembly and select Copy.
7. In the Copy assembly panel, select Translate and enter a Z offset of 15 mm.
Step 5: Run a Multi-Board Setup in Icepak
Figure 35.57: Copy Fan Panel
8. Click Apply to create the copy of the assembly.
Note:
The board trace properties are automatically copied to the new board with unique
names.
9. From the Macros menu, select Modeling > SIwave Icepak Coupling > PCB Iterator.
10. In the SIwave-Icepak Coupling Iterator for Single and Multiple PCBs panel, click New.
11. Select the BOARD_DCIR_solved PCB object and DCIR_solved SIwave project and set the Termin-
ation Convergence Criteria as shown in the image below.
12. Click New again and select the copied PCB object (BOARD_DCIR_solved.1) and DCIR_solved
SIwave project.
13. Set the Termination Convergence Criteria as shown in the image below.
Figure 35.58: SIwave-Icepak Coupling Iterator for Single and Multiple PCBs Panel
14. Click Accept to run the simulation. When the simulation is complete, the following panel appears.
15. Create the same two object faces for temperature and flow, while selecting all objects in both the
BOARD and BOARD.1 assemblies.
Step 5: Run a Multi-Board Setup in Icepak
Figure 35.59: Object Face - Temperature Contours
Figure 35.60: Object Face and Object Face Particles Panels

In this workshop, we performed a coupled simulation using Ansys SIwave and Ansys Icepak. The following
outlines the main steps:
• We ran a DC IR simulation in SIwave.
• We ran a coupled conduction-only simulation with Icepak using the initial DC IR results.
• We ran a coupled forced convection simulation with Icepak using the initial DC IR results.
• We displayed the temperature distrbutions from the coupled simulations in SIwave.
• We exported the SIwave project and launched it in Icepak.
• We ran the forced convection simulation defined in SIwave in the Icepak application on a single
board.
• We created a new Icepak project and copied the board to run a forced convection simulation on
multiple boards.
Chapter 36: TEC Macro Tutorial
36.1. Introduction
This tutorial demonstrates how to model a thermoelectric cooler (TEC) in Ansys Icepak.
• Load a TEC object from the Ansys Icepak Library
• Model a TEC using the Run TEC macro
• Postprocess the results of a model that includes a TEC
36.2. Prerequisites
This tutorial assumes that you have little experience with Ansys Icepak but that you are generally famil-
iar with the interface. If you are not, review Sample Session in the Icepak User's Guide and the tutorial
Finned Heat Sink of this guide. Some steps in the setup and solution procedure will not be shown ex-
plicitly.

A heat-generating IC package is on a PCB. Heat spreaders and a TEC are placed to cool the package.
TEC Macro Tutorial
Figure 36.1: TEC in Ansys Icepak

1. Open a new session of Ansys Icepak. When Icepak starts, the Welcome to Icepak panel opens.
2. Select Unpack and browse to your working directory.
3. In the File selection panel, select the file TEC_Tutorial.tzr and click Open to load the project.
This file is located on the Ansys Help Site. The procedure to download this file is described below.
2. Download the tec_tutorial.zip file here.
3. Unzip the tec_tutorial.zip file you have downloaded to your working directory.
4. In the Location for the unpacked project panel, browse to your working directory, enter a name
for your project, and click Unpack.
5. Inspect the model. Observe that an IC package is sitting on a PCB.
Figure 36.2: IC Package on PCB
6. Expand the Package assembly, right-click on the Package object, and select Edit to view its prop-
erties. On the Dimensions tab, note the Package type and Package thickness.
TEC Macro Tutorial
Figure 36.3: Package Object - Dimensions Tab
7. View the information in each of the other tabs in the Packages panel. Note the Die Total power
on the Die/Mold tab.
Figure 36.4: Package Object - Die/Mold Tab

We will use Thermoelectric Coolers (TECs) and heat spreaders as a primary means to cool this IC package.
TEC Macro Tutorial
1. To create a heat spreader on top of the package, create a block object and open its edit panel.
Note:
Ensure this block is not created inside an assembly.
2. On the Info tab, enter a Name of HeatSpreader1.
3. On the Geometry tab, set the geometry specifications as shown in Figure 36.5: HeatSpreader1 -
Geometry Tab (p. 878).
Figure 36.5: HeatSpreader1 - Geometry Tab
4. On the Properties tab, confirm the Block type is Solid with default materials selected.
Figure 36.6: Model with Heatspreader1 Added
5. Next, place a TEC on the heat spreader. This TEC will cool the IC package’s hot spot. Go to the Library
tab.
6. Expand Libraries, Main library, and TECs.
Figure 36.7: TECs Library
7. Locate the Laird_HT4_12_F2_3030 TEC and double click on it. The TEC is created in the model.
Return to the Project tab and confirm that the TEC is in the Model manager and Model Display
windows.
8. In the Model manager, right-click the Laird_HT4_12_F2_3030.1 assembly and select Move. Set
Rotate and Translate operations as shown in Figure 36.8: Move the TEC (p. 880).
Note:
You can use the Distance tool in the View menu to confirm the TEC is centered
above the package die.
TEC Macro Tutorial
Figure 36.8: Move the TEC
9. In the Model manager, expand the Laird_HT4_12_F2_3030.1 assembly and view the objects
composing the TEC.
Figure 36.9: Model with TEC Added
10. Create a heat spreader on top of the TEC (for the TEC hot side). Create another block object and
open its Edit panel.
11. On the Info tab, enter a Name of HeatSpreader2.
12. On the Geometry tab, set the geometry specifications as shown in Figure 36.10: HeatSpreader2 -
Geometry Tab (p. 881).
Figure 36.10: HeatSpreader2 - Geometry Tab
13. On the Properties tab, confirm the Block type is Solid with default materials selected.
TEC Macro Tutorial
Figure 36.11: Model with Heatspreader2 Added
14. Next, create wall objects that will allow heat to escape the domain. We will create 2 walls, one below
the PCB that represents natural convection in air, and one on top of the heat spreader that represents
a cold plate.
a. Create a wall object and open its Edit panel.
b. On the Info tab, name the wall object LowerWallBoundary, and in the Geometry tab, set
the geometry specifications as shown in Figure 36.12: LowerWallBoundary - Geometry
Tab (p. 883).
Figure 36.12: LowerWallBoundary - Geometry Tab
c. In the Properties tab under Thermal specification, click Edit and specify a 15 W/K-m2 Heat
transfer coefficient as shown in Figure 36.13: LowerWallBoundary - Property Tab (p. 884).
TEC Macro Tutorial
Figure 36.13: LowerWallBoundary - Property Tab
d. Create another Wall object and open its Edit panel.
e. On the Info tab, name the wall object UpperColdPlateWallBoundary, and in the Geometry
tab, set the geometry specifications as shown in Figure 36.14: UpperColdPlateWallBoundary
- Geometry Tab (p. 885).
Figure 36.14: UpperColdPlateWallBoundary - Geometry Tab
f. In the Properties tab under Thermal specifications, specify a 20C temperature boundary
condition as shown in Figure 36.15: UpperColdPlateWallBoundary - Property Tab (p. 886).
TEC Macro Tutorial
Figure 36.15: UpperColdPlateWallBoundary - Property Tab
15. In the Model manager, right-click the Cabinet and select Autoscale to resize it. Notice the air-solid
object already included in the model. This will be a conduction-only model and fluid flow effects
will be ignored.
Figure 36.16: Autoscaled Cabinet
36.6. Step 3: Creating Separately Meshed Assemblies

At this stage, we will apply non-conformal mesh settings.
1. In the Model manager, right-click on the Laird_HT4_12_F2_3030.1 assembly and select Create
assembly.
2. Double-click on the new assembly and enter a Name of TECs on the Info tab.
3. On the Meshing tab, enter the Slack settings as shown in Figure 36.17: TECs Assembly - Meshing
Tab (p. 888).
TEC Macro Tutorial
Figure 36.17: TECs Assembly - Meshing Tab
4. Leave the other default mesh settings. Click Update and Done.
5. In the Model manager, double-click the Package assembly and go to the Meshing tab.
6. Select Mesh separately and view the Slack settings.
Figure 36.18: Package Assembly - Meshing Tab
7. Click Update and Done to close the Assemblies panel. The Model manager should appear as shown
in Figure 36.19: Model Manager (p. 890).
TEC Macro Tutorial
Figure 36.19: Model Manager
Note:
Before continuing to generate a mesh, ensure the Model manager appears as it does
in the image above. If an object is included in an assembly erroneously, move it
outside the assembly before continuing.
1. Click the Generate mesh button ( ) to open the Mesh control panel.
2. Click Generate.
Step 5: Create Monitor Points
Figure 36.20: Mesh Control Panel
3. Use the Display tab and inspect the mesh in the Graphics Display window. Also, use the Quality
tab to confirm the mesh is of reasonable quality.
36.8. Step 5: Create Monitor Points

Create temperature monitor points by right-clicking on the tec cold source (tec-cold) and the package
object (560_BGA_39X39_4peripheral_p1.00) and selecting Monitor point from the Create menu.
TEC Macro Tutorial
Figure 36.21: Monitor Points Folder
Note:
Alternatively, you can click on these objects and drag them into the Points folder in
the Model manager.
Note:
By default, monitor points are created as temperature monitor points. No further edits
are required.
36.9. Define Physical and Numerical Settings

In the Model manager under Problem setup, double-click Basic parameters. Review the settings on
the General setup tab. Note that the model will solved for temperature only. Click Accept.
Figure 36.22: Basic Parameters Panel

overwrite your job file when it saves the model.) From the File menu, select Save project.
Note:
36.11. Calculate a Solution

To solve a model containing TEC objects, you must use the Run TEC macro.
TEC Macro Tutorial
1. Open the Run TEC panel as shown in Figure 36.23: Run TEC Macro (p. 894).
Figure 36.23: Run TEC Macro
2. In the Run TEC panel under Material properties, select Use Laird properties.
Note:
Alternatively, you can select Specify material properties and set the Seebeck
coefficient, Electrical resistivity, and Thermal Conductivity.
3. Under TEC Simulation Mode select Specify I and calculate T. This will operate the macro in tem-
perature-hunting mode.
4. In the TEC Objects List, specify 1.5 A for Operating Current. Leave the default values for G-factor
and # of TEC Couples.
5. Specify a Solution ID and click Accept to launch the solver.
Figure 36.24: Run TEC Panel
TEC Macro Tutorial
Examine the Results
Figure 36.26: Temperature Monitor Point Plot
36.12. Examine the Results

1. Create a plane cut to display temperature contours.
a. Click the Plane cut button ( ) to open the Plane cut panel.
TEC Macro Tutorial
Figure 36.27: Plane Cut Panel
b. For Set position, select Z plane through center.
c. Select Show contours. Temperature is the default contour selection.
d. Click Create and Done.
Figure 36.28: Plane Cut
2. Create a Summary report of the temperatures on the top and bottom ceramic objects along with
the heat flow in the cold and hot source objects.
a. In the Model manager, select tec-ceramic-bot, tec-ceramic-top, tec-cold, and tec-hot,

right-click the selection, and select Separate from the Summary report menu. The Define
summary report panel is displayed.
Examine the Results
Figure 36.29: Define Summary Report Panel
b. Select Report facet values.
c. Select Temperature as the Value for the ceramic objects and Heat flow as the Value for
the source objects.
d. Click Write to create the summary report.
Figure 36.30: Summary Report
e. From the File menu, click Save project.
TEC Macro Tutorial

In this tutorial, you used the Run TEC macro to model an IC package being cooled via a thermoelectric
cooler (TEC).
Some tips and best practices used in this tutorial are listed below:
• Ensure adequate heat sinking at the TEC hot side.
• Ensure adequate mesh resolution on the TEC objects. If necessary, this can be achieved through
per-object parameters and non-conformal meshing.
• Ensure correct TEC properties are entered in the Run TEC macro panel.
• Use monitor points on the TEC object to monitor convergence.
• Once a TEC is brought into your Icepak model, perform Move operations on the entire TEC as-
sembly.
• Make use of the Icepak Library to quickly insert TEC objects into your model. Also, note that the
Create TEC macro can be used to create custom TECs.
• Individual settings inside the edit panels of TEC objects should not be modified manually.
Chapter 37: Icepak-Twin Builder Coupling
37.1. Introduction
This tutorial demonstrates how to create and use a Reduced Ordered Model (ROM) using Ansys Icepak
and Ansys Twin Builder.
There are two steps to create ROM model:
• Create the step response files. These files can be created automatically using Icepak. This tutorial
demonstrates how to create the required step response files in Icepak.
• Create the ROM in Twin Builder. This tutorial also presents the procedure needed to create a
state-space model in Twin Builder.
37.2. Prerequisites
This tutorial assumes that you have basic familiarity with the Ansys Icepak and Ansys Twin Builder inter-
faces.

In this workshop, we have four FET’s (Field-effect transistor) placed on a board and a heat sink mounted
on one of the FET. These FET’s generate heat which gets dissipated into the environment. Forced con-
vection is used for thermal management of the system.
We are interested in temperature rise at the four FET’s due to its power dissipation. From a system point
of view, power dissipation from the FET’s are the inputs and the temperature rise at the four FET’s are
Icepak-Twin Builder Coupling
the outputs. We will create a ROM which can efficiently calculate temperatures at the pre defined outputs
under any transient heat dissipation scenario.
The state-space approach is generally valid for linear systems consisting of forced convection flow and
insignificant radiative heat transfer.
The input file Icepak_TwinBuilder.tzr can be found on the Ansys Help Site. The procedure to
2. Download the twinbuilder.zip file here.
3. Unzip the twinbuilder.zip file you have downloaded to your working directory.
37.4. Step 1: Unpack the TZR File

1. Create a working directory. Copy the file Icepak_TwinBuilder.tzr to your working directory.
2. Start Ansys Icepak, When Icepak starts, the Welcome to Icepak panel opens.
3. Click Unpack.
Figure 37.1: Welcome to Icepak
4. The File selection panel appears. In the File selection panel, select the Icepak_TwinBuilder.tzr file
from your working directory and click Open.
Step 1: Unpack the TZR File
Figure 37.2: File Selection Dialog
5. The Location for the unpacked project dialog appears. Select the working directory where you
would like to place the unpacked project file, a project name, such as Icepak-Twin Builder-
Project, in the New project text field, and then click Unpack.
Figure 37.3: Location for the Unpacked Project Dialog
Note:
Mesh and solver settings have already been defined for this model.
37.5. Step 2: Set up the State-space Trials

1. From the Solve menu, select Run optimization to open the Parameters and optimization panel.
Step 3: Enter Inputs and Outputs for State-space
Figure 37.4: Parameters and Optimization panel
Note:
Ensure that Write Twin Builder file is disabled.
2. For Trial type, select State-space.
37.6. Step 3: Enter Inputs and Outputs for State-space

1. On the Parameters and optimization panel, click the State-space tab.
2. From the Input drop-down, select FET1, FET2, FET3, and FET4 and click Accept.
Figure 37.5: State-space Inputs
3. From the Output drop-down, select FET1, FET2, FET3, and FET4 and click Accept.
Step 4: Run a Steady State Solution
Figure 37.6: State-space Outputs
Note:
The inputs can also be selected from the list of monitor points. When Icepak objects
are selected as inputs, Icepak will automatically create monitor points for these
components.
Note:
The inputs and the outputs can be different.
37.7. Step 4: Run a Steady State Solution

1. On the Parameters and optimization panel State-space tab, enter a Solution ID.
2. Click Run to run the steady state solution.
Figure 37.7: Enter a Solution ID and Run the Solution
Note:
The steady-state solution residuals appear as in the following images. Ensure that
the the solution is converged.
Note:
You can use parallel solve can for this solution. For parallel, ensure that Specify
monitor point output frequency is disabled in the Parallel settings panel.
Step 5: Run Transient Trials
Figure 37.8: Steady State Solution Residuals
3. Click Done to dismiss the solution residuals panels.
37.8. Step 5: Run Transient Trials

1. On the Parameters and optimization panel State-space tab under Solution type, select Transient.
2. Enter 5.0 W for the Input object power.
3. Next to Transient setup, click Set to automatically set the time step size and duration.
Note:
The automatic Set option sets simulation duration of 10,000 seconds to make sure
that the system reaches a steady state. This also uses smaller time step size at the
start to capture in initial transient behavior. Edit option can be used to change these
settings.
4. Next to Steady state solution, click Select to open the File selection dialog and browse for the
steady-state.fdat file.
Note:
Icepak restarts from a full data steady state solution and runs a transient energy only
solution (no flow).
Note:
Icepak generates step response data.
5. Enter a Trial ID prefix and click Run trials.
Figure 37.9: Set Up Transient Trials
Note:
For every input, Icepak runs one solution. For every output, Icepak creates step re-
sponse curves within each solution.
Note:
The concurrent solving ability in Icepak is not used for these runs.
Step 6: Create the ROM in Twin Builder
6. Note the trials residuals in the images below. Ensure that the solution is converged. The temperature
monitor point curves must be flat at the end.
Figure 37.10: Transient Trials Residuals
Note:
Icepak generates 16 monitor files, which are the step responses of the system. These
(.out) files are saved in the project directory within a directory named Twin BuilderFiles.
The following files are generated:
• [InputObjectName].[OutputObjectName].out
• [SolutionID].gif
• [SolutionID].simpinfo
• InputPortNames.txt
• InputStepInputValues.txt
This completes the generation of the step response data using Icepak. In the next section, we will
use the step response data to create a state-space model in Twin Builder.
37.9. Step 6: Create the ROM in Twin Builder

In Twin Builder, we will create a ROM model from the Icepak data and run the ROM for simple inputs.
1. Open Ansys EM Suite > Ansys Twin Builder.
2. From the Twin Builder menu, select Toolkit > Thermal Model Identification.
Figure 37.11: Thermal Model Identification
3. In the Thermal Model Identification dialog, do the following:
Step 6: Create the ROM in Twin Builder
Figure 37.12: Thermal Model Identification Dialog
a. For Number of Inputs, enter 4.
b. For Number of Outputs, enter 4.
c. For State Space Model Max Order, enter 14.
Note:
The maximum order for State Space Model Max Order is 40. It can be
optimized to smaller than 14 when possible.
d. Next to Response/Input File Location, click Browse.
e. In the Browse for Folder dialog, browse to and select the Icepak project working dir-
ectory.
Figure 37.13: Browse for Folder Dialog
f. Click OK to return to the Thermal Model Identification dialog.
g. Click Generate. After the ROM has been created, a message appears. Press any key to
close the message window.
Figure 37.14: ROM Creation Message
h. Click Close to close the Thermal Model Identification dialog.
Note:
Check the Message Manager after the ROM is created. If there are any
warnings or error messages, the accuracy of the result in Twin Builder
is not ensured.
Step 8: Enable Outputs
37.10. Step 7: Place the ROM in Twin Builder

1. In the Project Manager, expand Definitions and then Components.
Figure 37.15: Thermal ROM SML Component
2. Click and drag Thermal_ROM_SML into the workspace. Click to place it in the workspace and then
press the ESC key.
Figure 37.16: Thermal ROM SML in the Workspace
37.11. Step 8: Enable Outputs

1. From the Twin Builder menu, select Output Dialog.
2. Under Add/Remove, expand Thermal_ROM_SML1.
3. Select all four outputs as shown in the image below.
Figure 37.17: Output Dialog
4. Click OK to close the Output Dialog.
37.12. Step 9: Specify Inputs
Note:
If the Component Libraries window is not displayed, click View > Component Libraries.
1. On the Components tab of the Component Libraries window, expand Simplorer Elements > Basic
Elements > Blocks > Sources Blocks.
Step 9: Specify Inputs
2. Click and drag CONST: Constant Value to the workspace and connect it to input1_fet1. Click with
the left mouse button to place the block.
3. Repeat the previous step to connect CONST: Constant Value blocks to input2_fet4 and input3_fet2.
4. In the Component Libraries window, expand Simplorer Elements > Basic Elements > Tools >
Time Functions.
5. Click and drag TRAPEZ: Trapezoidal Wave to the workspace and connect it to input4_fet3. Click
with the left mouse button to place the block.
Figure 37.18: ROM Schematic
6. Double-click the CONST1 block to open its Parameters panel.
7. Under Parameters next to Value, enter 1.5 to specify the power dissipation (in Watts) for the ROM
and click OK.
Figure 37.19: CONST1 Parameters Dialog
8. Repeat the previous step for CONST2 and CONST3.
9. Double-click the TRAPEZ1 block to open its Parameters panel.
Step 10: Plot Outputs
Figure 37.20: TRAPEZ1 Parameters Dialog
10. Under Parameters, do the following:
a. For Amplitude, enter 1.5.
b. Select Period and enter 50.
c. For Periodical, select Yes.
d. For Rise Time, enter 0.1.
e. For Fall Time, ente 0.1.
f. For Pulse Width, enter 5.
11. Under Outputs, deselect Value.
37.13. Step 10: Plot Outputs

1. In the Project Manager, right-click Results and select Create Standard Report > Rectangular Plot.
Figure 37.21: Create a Rectangular Plot Report
2. In the Report dialog under Quantity, select all four outputs as shown in the image below.
Figure 37.22: Report Dialog
3. Click New Report.
Step 11: Simulate ROM
37.14. Step 11: Simulate ROM

1. In the Project Manager, expand Analysis and double-click TR to open the Transient Analysis
Setup dialog.
Figure 37.23: Transient Analysis Setup Dialog
2. Under Analysis Control, do the following:
Note:
Ensure that you select second as the unit for the following entries.
a. For End Time - Tend, enter 1000 s.
b. For Min Time Step - Hmin, enter 0.1 s.
c. For Max Time Step - Hmax, enter 4 s.
3. Click OK to close the Transient Analysis Setup dialog.
4. In the Project Manager, right-click on TR and select Analyze.
Figure 37.24: Analyze the ROM
5. Under Results, select the XY Plot to display the temperature change.
Step 6: Summary
Figure 37.25: XY Plot with Temperature Results
Note:
Temperatures are dispalyed in Kelvin. The XY plot created is based on both step responses
created by Icepak and the inputs of Twin Builder.

In this tutorial, we created a reduced order model in Ansys Twin Builder and the step response files
necessary to create and analyze a state-space model in Ansys Icepak.
Chapter 38: CTM Import and RedHawk Back
Annotation
38.1. Introduction
This workshop serves to demonstrate the Ansys Icepak portion of the Ansys Chip-Package-System (CPS)
thermal workflow. In this tutorial, you will:
• Begin with an existing Icepak project that contains a PCB with some components, including a
detailed IC package
• Import a CTM-based power map onto the detailed package die
• Perform a system level thermal simulation
• Export the relevant system-level thermal information for import to a chip-level thermal analysis
tool
Review the components of the model components in the following image.
CTM Import and RedHawk Back Annotation
Note:
38.2. Unpack the Ansys Icepak Project

• Open a new, standalone Icepak session and click Unpack.
Figure 38.1: Options Available for a New Icepak Session
• In the file selection panel, select the packed project file IPK_RH.tzr and click Open.
Note:
The file IPK_RH.tzr can be found on the Ansys Help Site. The procedure to download
this file is described below.
Unpack the Ansys Icepak Project
2. Download the chip-package-system.zip file here.
3. Unzip the chip-package-system.zip file you have downloaded to your working

directory.
Figure 38.2: File Selection Panel
• In the location for the unpacked project file selection dialog, select a location where you would like
to create the new Icepak project and click Unpack.
Note:
A directory with the project name will be created. All project data will be saved in
this directory.
• Figure 38.3: Unpacked Model
38.3. Set Project Units

1. From the Edit menu, select Preferences.
2. Under Defaults, select Units.
3. Under Category, select Length.
4. Ensure that Length is set to mm and Volume Flow is set to cfm.
Check Custom Material Properties
Figure 38.4: Preferences Panel
5. Click Set all to defaults.
6. Click This project.
38.4. Check Custom Material Properties

Confirm that the properties of the custom package materials, which have already been defined. These
materials should be consistent with those specified in the chip-level thermal analysis.
1. In the model tree, expand Materials and Solid.
2. Expand Dielectric, Ic-pkg_custom, and Solder_custom.
Figure 38.5: Custom Materials
3. Double-click the materials under each to verify the material settings in the images below.
Figure 38.6: Materials Panel (BT)
Check Custom Material Properties
Figure 38.7: Materials Panel (Quantum QMI 301)
Figure 38.8: Materials Panel (64SN 37PB)
38.5. Review the Package Object

Review the package object properties, display traces, and view the metal fractions.
1. On the model manager Project tab, double-click the fccsp package object.
2. Ensure the settings on the Package panel Dimensions, Substrate, Solder, and Die/Mold tabs
match those in the images below.
Review the Package Object
Figure 38.9: Package Panel (Dimensions Tab)
Figure 38.10: Package Panel (Substrate Tab)
Review the Package Object
Figure 38.11: Package Panel (Solder and Die/Mold Tabs)
3. Right-click on the package in the model tree.
4. From the right-click menu, select Traces > Color by trace to display the traces in the Graphics
window.
Figure 38.12: Traces
Icepak uses the package traces to determine detailed, layer-by-layer, local metal fractions in
the package. The metal fractions are then used to determine local thermal properties (for ex-
ample, thermal conductivity). Hence detailed thermal pathways in the package object are re-
solved.
5. From the Model menu, select Show metal fractions to open the Show metal fractions panel.
6. From the Object with traces drop-down list, select fccsp.
7. From the Trace layer drop-down list, select M1 (TOP) and click Display.
Figure 38.13: Show Metal Fractions Panel
8. Examine the metal fractions in the Graphics window.
Import RedHawk CTM Profile
Figure 38.14: Metal Fractions (M1 TOP)
9. Review each layer's metal fractions by selecting them in the Trace layer drop-down list and
then close the panel.
38.6. Import RedHawk CTM Profile

1. From the File menu, select Import > Powermaps > RedHawk CTM profile to open the Import
CTM profile files panel.
2. From the Die Block drop-down list, expand the fccsp package, select flipdie_block_FCHIP,
and click Accept.
3. Next to CTM file, click Browse and use the CTM file dialog box to locate and select the CTM
file.
4. Click Load to load the file.
Figure 38.15: Import CTM Profile Files Panel
Note:
If you have a Pd map, you can import it as an altnernative to the CTM profile. Open
the Import Apache Sentinal TI profile panel from File > Import > Powermaps >
Apache Sentinel TI profile. For flip-chip packages, select Face down.
5. Under CTM Data, click View for one of temperature points to open the Powermap info panel.
6. Zoom in on the die to view the power profile at the selected temperature. The CTM viewer
plots the power map as a function of temperature on 10 micron x 10 micron cells.
Figure 38.16: Powermap Info Panel
7. In the Import CTM profile files panel, view the power profile at each temperature point. Note
that, as temperature increases, power also increases.
8. For Density number as 101 and the Resolution(*n) as 4.
Figure 38.17: Powermap
9. Click Apply to generate the powermap. The powermap is displayed in the Graphics window,
and source objects are created in an assembly in the model tree.
Note:
After creating the powermap, the associated files are created in the project
folder. The current powermap can be replaced by changing the Density number
in the Import CTM profile files panel and clicking Apply.
Figure 38.18: Powermap
10. Ensure that the powermap corresponding to Density number 101 is loaded, and click Done
to close the Import CTM profile files panel.
11. Adjust the location of the powermap to center it and place it on the bottom of the die. First,
double-click the fccsp package object in the model tree and click the Dimensions tab.
12. Click Component visibility to open the Component Visibility panel, ensure only Die is selected,
and click Done in both panels.
Figure 38.19: Packages Panel - Dimensions Tab
13. Click Align Face Centers ( ) and use the tool to select the powermap assembly and the bottom
face (-Z direction) of the die to move it to the bottom face.
Note:
You can use the View/Distance tool to ensure that the powermap is centered
on the bottom face.
Generate the Mesh
Figure 38.20: Align Face Centers
14. Double-click the fccsp package object in the model tree and edit the Component visibility
settings to display all components.
38.7. Generate the Mesh

Before generating the mesh, define non-conformal mesh settings to avoid mesh bleeding and minimize
cell count as well as per-object mesh settings to ensure a good grid transition between the assembly
non-conformal mesh and the background mesh.
1. Create an assembly that includes the fccsp package and the powermap assembly. Press and
hold the Ctrl key to select the fccsp-powermap assembly and the fccsp package object. Right-
click and select Create Assembly. Change the name of the newly created assembly to fccsp-
assembly.
2. Double-click the fccsp-assembly to open the assemblies panel. On the Meshing tab, select
Mesh separately and ensure the settings match those in the following image.
Figure 38.21: Assemblies Panel - Meshing Tab (fccsp-assembly)
3. Double-click the fccsp-powermap assembly to open the assemblies panel. On the Meshing
tab, select Mesh separately and ensure the settings match those in the following image.
Generate the Mesh
Figure 38.22: Assemblies Panel - Meshing Tab (fccsp-powermap)
4. Ensure the model tree appears as it does in the following image.
Figure 38.23: Updated Model Tree
5. Click the Generate mesh button ( ) to open the Mesh control panel.
6. On the Local tab, click Edit params to open the Per-object meshing parameters panel.
7. Select the fccsp-assembly, and select the Outside X count and Outside Y count check boxes,
8. Enter 10 for the requested values, and click Done.
Generate the Mesh
Figure 38.24: Per-object Mesh Settings
9. On the Mesh control panel, click Generate to generate the mesh.
10. After the mesh is generated, click the Display tab, select Display mesh.
11. Under Display attributes, select Cut plane.
Figure 38.25: Mesh Cut Plane
Note:
It is recommended that you perform a grid sensitivity study when working with your
own models. For the purposes of this tutorial, we will assume the mesh is acceptable.
38.8. Run the Simulation

The solution settings and parameters are already defined by the unpacked archive (.tzr) file. If desired,
open the Basic parameters and Basic settings panels to review them. Also, three monitor points are
also already defined. If desired, review in the model tree in the Points folder.
1. From the Solve menu, select Run solution to open the Solve panel.
Run the Simulation
Figure 38.26: Solve Panel
Note:
Sequential solution of flow and energy equations speeds up forced convection

problems.
2. Click Start solution to run the simulation.
Figure 38.27: Solution Residuals Panel
Post-Process the Solution
Figure 38.28: Monitor Panels
38.9. Post-Process the Solution

Post-process the solution by creating object faces and a summary report.
1. Click the object face button ( ) to open the Object face panel.
2. From the Object drop-down select the fccsp-powermap assembly and click Accept.
3. Select Show contours and click Parameters to open the Object face contours panel.
Figure 38.29: Object Face Panel
4. In the Object face contours panel, ensure Temperature is selected, and select This object.
Figure 38.30: Object Face Contours Panel
5. Click Done in the Object face contours panel and then Done again in the Object face panel
to display the temperature contours.
Figure 38.31: Powermap Temperature Contours
6. To determine the heat transfer coefficient range on the package object, create a summary report
by selecting Report > Summary report to open the Define summary report panel.
7. Define the report entries as shown in the image below, selecting the substrate an die objects
under the fccsp package and setting Heat tr coefficient as the Value.
Figure 38.32: Define Summary Report Panel
8. Click Write to display the summary report.
Figure 38.33: Report Summary data Panel
9. Note the minimum and maximum values in the report (0 and 295.756, respectively). We will
input these values when creating an object face to display the heat transfer coefficient on the
substrate and die blocks. Click Done to close the summary report, and click Close to close the
Define summary report panel.
Note:
Negative values correspond to heat entering the object at that surface.
10. From the Post menu, select Object face (facet) to open the Object face (facet) panel.
11. Enter a Name of fccsp-htc.
12. In the Object drop-down list, expand the fccsp package and select the substrate and three die
objects.
13. In the Contours of drop-down list, select Heat transfer coefficent.
14. Under Color levels, select Specified and enter 295.756 for the Max value.
Figure 38.34: Object Face (Facet) Panel
15. Click Display to display the object face in the Graphics window.
Figure 38.35: Heat Transfer Coefficient Contours
16. Close the Object face (facet) panel.
17. If desired, create additional post-processing objects, such as a cut plane displaying velocity
vectors as displayed in the following image.
Figure 38.36: Heat Transfer Coefficient Contours and Cut Plane of Velocity Vectors
Export Data
38.10. Export Data

You can export temperature data at each tile to RedHawk. Also, the heat transfer coefficient on the
package boundary computed by Icepak can be used as the new boundary condition in the chip-level
thermal analysis in Sentinel-TI.
1. From the Report > Export menu, select RedHawk Back Annotation to open the RedHawk
Back Annotations panel.
2. In the Back annotation file field, specify a location for saving the exported data.
Figure 38.37: RedHawk Back Annotations Panel
3. Click Write to export the data.
4. From the Report > Export menu, select Sentinel TI HTC File to open the Export Sentinel TI
HTC file panel.
5. For Package top object, expand the fccsp package object and select flipdie_block_FCHIP.
6. For Package substrate object, expand the fccsp package object and select substrate.
7. For Package bottom object, expand the fccsp package object and select any solder ball.
Figure 38.38: RedHawk Back Annotations Panel
8. Enter a File name and click Write to export the data.
38.11. Summary
In this tutorial, you have:
• Imported the CTM-based, temperature-dependent chip power map onto the IC package die
• Setup, meshed, and solved the Icepak model as a standard Icepak project
• Postprocessed the Icepak chip-aware model
– Viewed temperature profile on the chip power map
– Viewed heat transfer coefficients on the IC package boundary
• Exported the system-level thermal information for chip-level thermal analysis
Chip-Package-System (CPS) thermal analysis using Ansys Icepak is important:
• Chip-level thermal simulation is coupled to the system level thermal environment (Icepak)
• Provides more accurate chip-level thermal results (i.e. system aware chip design) compared to
using assumed environment conditions
– For example, averaged and/or assumed htc on the package boundary, or uniform and/or
assumed die temperature
• Provides more accurate system-level thermal results (i.e. chip-aware system thermal design)
• Provides convenient, straight-forward method to accurately identify hot spots in chip and package
Summary
• Offers the ability to perform chip/package thermal optimization
• Capability of chip-level tool (RH-CTA) to take into account thermal results from Icepak to compute
chip-level thermal phenomena offers an unequaled level of accuracy for thermal design of chips
and packages
IDF, 335, 349
Index trace layer, 353, 437
individual side specification, 114
A
Airborne Electronics System, 761 J
Avionics Box, 579 Joule heating, 369
B L
BGA-package, 223, 421-422 loss coefficient, 203
loss coefficient vs Re, 220
C
CFD Post, 465 M
CFD Post in Workbench, 465 Maxwell and Icepak, 777
cold-plate, 135-136 MCAD Geometry
CTM Import, 925 Design Modeler, 649
mesh exercise, 185
D microelectronics, 387
Datacenter cooling modeling
high density, 509 radiation, 280
Design Modeler monitor point, 402
electronics, 553 mouse conventions, 2
MCAD Geometry, 649 MRF, 743
Dimensions tab, 423 multi-level meshing, 409, 413
E N
Edit object panel, 8 non-conformal
Electronics assembly, 141
Design Modeler, 553 mesh, 169, 177, 179
nested, 158
F
finned heat sink, 5, 19
O
Functions object parameters, 315
compound, 251 obtaining support, 2
objective, 251 optimization run, 256
primary, 251 orthotropic material properties, 154
H P
heat pipe, 151, 158 param value, 248
heat sink, 65 parameterization, 103
finned, 5, 19 parametric runs, 228
inline or staggered, 223 parametric trials
heat transfer coefficient, 428 multiple trials, 122
help
obtaining support, 2 R
radiation model
I discrete ordinates, 265, 282
Icepak in Workbench, 447 ray tracing, 283
Icepak – HFSS coupling, 807 rf amplifier, 51, 69
Icepak-Twin Builder coupling, 901
import
Index
S
search fan library, 66
SIwave - Icepak coupling, 823
SpaceClaim - Icepak coupling, 619, 673
summary report, 176
support
obtaining help, 2
System
Electronics, 761
System-Level Geometry
Translation, 689
T
TEC macro, 873
Thermal Resistance, 245
trace heating, 369
trace layer, 347
import, 353, 437
transient simulation, 289
Translation
MCAD Geometry, 689
typographical conventions, 2
W
Workbench
Icepak, 447
Maxwell and Icepak, 777
Z
zero slack, 190, 435, 441
zoom-in modeling, 311, 321

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Ansys Icepak Tutorials 2021 R2

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Ansys Icepak Tutorials

ANSYS, Inc. Release 2021 R2

© 2021 ANSYS, Inc. Unauthorized use, distribution or duplication is prohibited.

U.S. Government Rights

Published in the U.S.A.

4.15. Step 12: Summary ....................................................................................................................... 131

8.5. Loading the Model ........................................................................................................................ 186

11.13. Step 10: Optimization in DesignXplorer ...................................................................................... 256

14.18. Step 15: Additional Exercise 2 .................................................................................................... 331

18.10. Step 7: Examine the Results ....................................................................................................... 403

22.9. Step 6: Calculate a Solution .......................................................................................................... 457

26.12. Additional Exercises .................................................................................................................. 613

30.12. Simple Shapes vs. Complex Shapes ............................................................................................ 699

35.5. Step 2: Run an SIwave Simulation ................................................................................................ 824

3.26. Problem setup wizard at step 5 of 14 ................................................................................................... 81

6.6. Turbulent Flow and Initial Z Velocity .................................................................................................... 162

12.4. Dimensions of the hs-base ................................................................................................................ 269

15.6. IDF import Panel - Miscellaneous options .......................................................................................... 341

20.2. Display of Traces ............................................................................................................................... 425

23.38. Plot of TemperatureVariation Along ForChart ................................................................................... 497

25.13. Hub/Casing Faces Selection ............................................................................................................. 565

27.48. Mesh Warnings ............................................................................................................................... 646

29.18. Updated Project Schematic ............................................................................................................. 684

30.46. Updated Tree Outline View .............................................................................................................. 718

31.18. Contour of Speed at Center of Z with MRF ........................................................................................ 759

35.19. Export ANF File in Generic Format ................................................................................................... 837

36.10. HeatSpreader2 - Geometry Tab ........................................................................................................ 881

38.6. Materials Panel (BT) ........................................................................................................................... 930

1.2. How To Use This Manual

1.2.1. For the Beginner

1.2.2. For the Experienced User

1.3. Typographical Conventions Used In This Manual

Model → Generate mesh

Problem setup → Basic parameters

1.4. Mouse Conventions Used In This Manual

1.5. When To Call Your Ansys Icepak Support Engineer

3. Write down the exact error message that appeared, if any.

In this tutorial you will learn how to:

• Create a new project.

• Create a model using blocks, openings, fans, sources, and plates.

• Generate a mesh for your model.

2.3. Problem Description

Figure 2.1: Problem Specification

2.4. Step 1: Create a New Project

The New project panel appears.

3. Specify a name for your project and click Create.

2.5. Step 2: Build the Model

1. Resize the default cabinet in the Cabinet panel.

a. In the Cabinet panel, click the Geometry tab.

b. Under Location, enter the following coordinates:

c. Click Done to resize the cabinet and close the panel.

• Double-click the object in the Model manager window, or

– Click the Edit icon ( ) in the model toolbar.

2. Create the backing plate.

a. Click the Create blocks button ( ) to create a new block.

b. Click the Edit object button ( ) to open the Blocks panel.

c. Click the Geometry tab.

d. Enter the following coordinates for the block:

e. Click Done to modify the block and close the panel.

a. Click the Create openings button ( ) to create a new opening.

b. Click the Edit object button ( ) to open the Openings panel.

c. Click the Geometry tab.

d. Enter the following coordinates for the opening:

e. Click Done to modify the opening and close the panel.