THERMAL ANALYSIS OF PERFORATED FIN ARRAYS APPLYING

TAGUCHI METHOD

Dhanawade Hanamant S1*, K. N. Vijaykumar2, Dhanawade Kavita H.3

1* Professor, Smt. Indira Gandhi College of Engineering, Navi Mumbai, Pin-400709, India
(Research Scholar JJT University), dhanashri_hd@rediffmail.com
2. Professor and Head of Dept. of Mechanical Engineering, D. J Sanghvi College of Engineering,Mumbai,
3, Asst. professor in Dept. of Mechanical Engineering, Lokmanya Tilak College of Engineering, Navi Mumbai,

ABSTRACT

Heat dissipation is a drastic issue to tackle due to continued integration, miniaturization,

compacting and lightning of equipment. Heat dissipaters are not only chosen for their thermal
performance; but also for other design parameters that includes weight, cost and reliability,
depending on application. Development of super heat exchangers requires fabrication of
efficient techniques to exchange great amount of heat between surface such as extended
surface and ambient fluid. For instant, weight and reliability are important for space
applications. The present paper reports, an experimental study to investigate the heat transfer
enhancement in square fin arrays with circular perforation equipped on horizontal flat surface

The data used in performance analyses were obtained experimentally for various materials
like mild steel, copper, and aluminum, by different heat inputs and geometrical conditions.
Using the Taguchi experimental design method parameters influencing the rate of heat
transfer were investigated. Heat transfer coefficient was considered as performance
parameters. An L9 (33) orthogonal array was selected as an experimental plan. Result shows
that new perforated fins have higher rate heat transfer and considerable weight reduction in
comparison with solid fins.

Keywords
Heat transfer enhancement, Thermal performance, perforated fins, Natural convection, Taguchi method.
3
Vsolid Volume of solid fin, m
NOMENCLATURE Ø Porosity ratio.

Ab Surface area of bottom of the base, m2 1. INTRODUCTION

As Surface area of side of the base, m2
2
Aa Convective heat transfer area, m
dxb, dxs Distance of thermocouple below and side of
the bottom plate in the insulating brick, m
H Fin height, mm
2
ha Convective heat transfer coefficient, W/m K
k Thermal conductivity, W/mK
kb Thermal conductivity of insulating brick, W/mK
L Length of fin, m
Ta Ambient temperature, K
Ts Average surface temperature of a fin, K
dtb,dts Difference of temperatures at below and side
of the bottom plate in the insulating brick at
dxb and dxs respectively, K
3
Vvoid Removed volume of the perforated fin, m
The enhancement of heat transfer is an important
subject of thermal engineering. The removal of
excessive heat from system components is essential
to avoid the damaging effects of burning or
overheating. The heat transfer from surface may, in
general, be enhanced by increasing the heat transfer
coefficient between a surface and its surrounding, or
by increasing heat transfer area of the surface, or by
both. Extended surface that are well known as fins
are commonly used to enhance heat transfer in many
industries.
The long life and reliable performance of a
component may be achieved by effectively
controlling device operating temperature within the
limits set by the design engineers. With the increase
in heat dissipation from the electronic devices and
the reduction in overall form factors, it became an
essential practice to optimize heat sink designs with
least trade-offs
offs in material and manufacturing costs.
Heat dissipaters are not only chosen for their thermal
performance but also for design parameters like li
weight, cost and reliability. Depending on the
application, different priorities will influence design
parameters. For instance, weight and reliability are
important for space applications. Therefore various
types of fins like rectangular plate fins, square
sq pinfins
and circular pinfins are commonly used for both
natural and forced convection heat transfers.
Abdullah H. AIEssa et. al. [1-4]4] studied the heat
dissipation from a horizontal rectangular fin
embedded with square perforation, rectangular
perforations with aspect ratio of two, equilateral
triangular perforations of bases parallel and towards
its fin tip, by using finite element
lement technique under
natural convection. They compared the results of the
perforated fin with its external dimensionally
equivalent solid fins. They showed that perforation in
the fins enhances heat dissipation rates and at the
same time decreases the expenditure
penditure of the fin
material. Sanjeev D. Suryawanshi and Narayan K.
Sane [5]] investigated experimentally the heat
dissipation from fin array with inverted notch at the
central bottom portion of fin to modify its geometry for
enhancement of heat transfer on normal and inverted
notched fin arrays (INFAs). They found that the
average heat transfer coefficient for INFAs is nearly
30–40%
40% higher as compared with normal array. Md.
Souidi and Bontemps [6]] studied countercurrent gas-
gas
liquid flow in narrow rectangular channels simulated
by plain and perforated fins. They observed different
flow patterns depending on fluid flow rates. S.S.
Sane et. al. [7] worked on rectangular notched fin
arrays. They reported that, total heat flux as well as
the heat transfer coefficient increases as the notch
depth increases.
plate. The electric power input to the heater was
controlled by a variable transformer to obtain the
constant heat flux along the test plate.
The calibrated copper constantan thermocouples
were used for forming the junctions at different
points. One of the thermocouple was suspended
inside the enclosure to measure ambient
temperature. Total 16 thermocouples were fixed to
the fins,
ns, in such a way that the point at a fin becomes
the junction for measuring average temperature of an
array. Two thermocouples were fixed on upper plate
with help of nut. Other four thermocouples were
employed to measure the temperature across side &
bottom
om of the base to find out various heat losses to
the surrounding. Whole assembly was enclosed in
the enclosure to provide the natural convection
condition during the testing. The terminals of the
thermocouple were brought to a panel board outside
the enclosure.
osure. The calibrated digital temperature
o
indicator having 0 to 600 C was used to measure the
temperatures. Schematic of perforated fin array with
Circular perforation is shown in fig.1 and assembly of
experimentation
imentation is as shown in fig.2.
Fins were tested for two different size of
perforation of each material. After achieving the
steady state, readings of all temperatures were
noted. Observations were repeated to confirm validity
and the readings obtained were found to be similar.

2. EXPERIMENTAL SET UP

The experimental set up consists of the main

enclosure, Insulating bricks, Ceramic basin, upper
and bottom plates (120mm X 120 mm X12mm) and
fins. Fins were fixed uniformly on the horizontal
slotted upper plate. Fins of various materials were
used for testing. A heating unit, 1000watt nickel
Fig.1
1 Perforated Fin Array with Circular
chromium resistive heating coil was circulated in the
slot of ceramic basin. The ceramic basin was Perforation of 20mm
sandwiched between upper slotted plate and bottom
 Fig.2 Experimental set up

3. EXPERIMENTAL PLAN AND DATA ANALYSIS

3
1. Taguchi Method Orthogonal array L9(3 ) [8] experimental design
method was chosen to determine the experimental
The Taguchi method involves reducing the plan. In this study the control parameters porosity,
variation in a process through robust design of heat input, and thermal conductivity of material
experiments. The overall objective of the method is were set as a level as shown in Table1. In order to
to produce high quality product at low cost to the observe the effect of noise to source ratio on heat
manufacturer. The Taguchi method was developed transfer coefficient each experiment was repeated
3
by Dr. Genichi Taguchi, a method for designing three times under the same condition as per L9(3 )
experiments to investigate how different parameters table. Values were determined by comparing the
affect the mean and variance of process standard method and analysis of variance (ANOVA)
performance characteristics that defines how well which is based on the Taguchi method. The aim
the process is functioning. Taguchi method gives was to obtain performance characteristics
the S/N ratio as the performance index to evaluate (maximum heat transfer coefficient) hence Larger
the characteristics of the product or process. It can the better was chosen.
be easily defined as the ratio of the mean (signal) to
the standard deviation (noise) by S/N ratio. The S/N
ratios may be depended on the particular type of Table1. Control Parameters and Levels for
performance characteristics, including smaller-is- Maximum Heat Transfer Coefficient
better (ZS) or larger-is-better (ZL)
1 n
 Level Level Level
z s = − 10 log 
n
∑Y
i =1
i
2


Control parameters
I II III
(1)
1 n
1  A Porosity ratio 0 0.38 0.5
zL = − 10 log 
n ∑ Y i 
2
 i =1
(2) B Heat input (watt) 40 60 80
Where n is number of tests in trial Yi is the C Material (Thermal
Cu Al MS
th
performance value of i experiment. Conductivity)
2. Data Analysis (Experimentation) example, the mean S/N ratio for the heat input level
II can be calculated by averaging the S/N ratios for
The net convective heat transfer rate QNt from experiment no. 1, 4, 7, and for level II experiment
electrically heated test surface is calculated by no. 2, 5, 8 and for level III experiment no 3, 6, 9.
using The mean S/N ratio for each level of the other
QNt = Qelect – Qcond (3) parameters can be computed in similar manner that
Where Q indicates the heat transfer rate in which are presented in the response Table 3. The main
subscripts elect, cond, denote electrical, and effect of each parameter is nothing but difference of
conduction. The electrical heat input is calculated highest and lowest value among the levels.
from the electrical potential and current supplied to
the surface. The radiation heat loss is neglected. Table 2. Orthogonal Array L9(33) of the
The side wall and bottom surface of test plate were Experimental Results And Corresponding S/N
well insulated using insulating bricks. Ratio
The conductive heat losses were calculated as
Heat loss from bottom of base plate Experim ha S/N
A B C
Qbase =
−kAb dtb
(4) ent no. (w/m2k) Ratio
dxb 1 1 1 1 9.0 19.08
and Heat loss from side of base plate 2 1 2 2 9.3 19.37
− kAs dt s 3 1 3 3 8.65 18.74
Qside = (5)
dx s 4 2 1 2 9.1 19.18
The net heat transfer rate from the test section by 5 2 2 3 8.56 18.65
convection was calculated by using equation.
6 2 3 1 10.83 20.69
QN = haAa (Ts-Ta) (6) 7 3 1 3 9.24 19.31
Average heat transfer coefficient calculated by
8 3 2 1 12.38 21.85
using equation.
9 3 3 2 13.07 22.33
QN
ha = (7)
Aa (T s − Ta ) Table 3 .S/N Response Table for Maximum
Heat Transfer Coefficient
Porosity ratio (ø) =Vvoid /Vsolid

4. RESULT AND DISCUSSIONS Para Level Level Main

Level I
1. Taguchi and ANOVA Analysis. meters II III effects
From experimental readings, the average heat (A)Porosity 19.06 19.51 21.16a 2.1
transfer coefficient (ha) was calculated using (B)Heat a
19.19 19.96 20.59 1.4
Eqs.(7). Eqs.(2) larger is the better was used to Input
calculate the S/N ratio. Both the values of ha and (C)Thermal a
20.54 20.29 18.90 1.64
S/N ratio, are presented in Table 2. After calculating Conductivity
S/N ratio for each experiment the average S/N
value is calculated for each factor and level. For
22

21
Characteristics
Performance

20

19

18
0 0.44 0.66 40 60 80 Cu Al MS
Porosity Heat Input Mterial

Fig.3 the Effect of Each Parameter on Heat Transfer Coefficient

 The plots in fig.3 show the degree of influence of
the parameters on the performance characteristics.
The procedure can be explained with an example, for
an instance fig 3 shows the variation of the
performance characteristics with the porosity ratio.
Now let us try to determine the experimental
condition for first data point. The porosity ratio for this
point is 0, which is level I, the performance
characteristics value is 19.06 which are tabulated in
Table 3. Similarly for second data point, the
performance characteristics value is 19.51 under
level II. Similarly for third data point and so on.
The numerical value of the maximum point in each
graph shows the best value of that particular
parameter. They also indicate the optimum
conditions in the range of the experimental
conditions. The most effective parameter to enhance
Table 4 ANOVA to Maximize Heat Transfer Coefficient
Factors SS
A 11.19
B 4.54
C 6.54
Error 0.2864
Total 22.55
60
50
% Contribution
40
30
20
10
0 individual effect of the parameters A3,B3 and C1
Porosity Heat Input Thermal Cond.
Fig.4 Percentage Contribution of Each Control
Parameter to Enhance the Heat Transfer
2 Confirmation test
In this study ANOVA was used to analyze the
effects of porosity, heat input and thermal
conductivity of material on heat transfer coefficient.
ANOVAs is the statistical method used for
determine individual interactions of all control
parameter. In the analysis, the percentage
distributions of each control factor were used to
measure the corresponding effects on the
performance characteristics. This analysis was
the heat transfer rate is the porosity ratio. Fig.3
shows that the design parameter combination A3 B3
C1, and the corresponding values of each factors for
the maximum heat transfer coefficient i.e. A3
porosity ratio (0.5), B3 heat input (80), material
(Copper).
Table 4 summarizes the ANOVA results for
maximum heat transfer coefficient and shows
percentage contribution and variance of factors A B
and C. fig 4 indicates that porosity ratio having 50.23
% contribution and more significant, material (thermal
conductivity) having 29.38% contribution and heat
input having 20.39%contribution and less significant
influence upon the maximum heat transfer coefficient
in our study.
%
DOF MS F actual
Contribution
2 5.59 41.70 50.23
2 2.27 16.93 20.39
2 3.27 24.39 29.38
2 0.1341 - --
8 - - 100
carried out for a level of significance of 5% , ie for
95% level of confidence. ANOVAs values
belonging to the experimental results for the heat
transfer coefficient and S/N ratios are shown in
table no.2. The optimal heat transfer coefficient
were obtained by taking into account the influential
parameter within the evaluated optimum
combination. The predicated optimum heat
transfer coefficient was calculated by considering
and their levels using Eqs.(8)
(ha)p =Tha+(A3-)+(B3- Tha)+(C1- Tha) (8)
Where Tha is the total mean value of the heat
transfer coefficient. A3, B3, and C1 are the
(11.56,10.85 and 10.73) ha of experimental trials
at the corresponding parameter. The optimal heat
2
transfer coefficient is computed as 13.13 (w/m k).
The confidence interval for the predicated optimal
values is calculated as follows
ଵ ଵ
CI = ට‫ܨ‬௔௏భ ௏మ ܸ௘௣ ൬ + ൰ (9)
ఎ೐೑೑ ௥
Where ‫ܨ‬௔௏భ௏మ is the F-ratio required for (α=0.05
with a confidence of 95%) ܸଵ, ܸଶ are the number of
degree of freedom of the mean and number of
degree of freedom of error, ܸ௘௣ is the error of • Average heat transfer coefficient shows
variance, r is the number confirmation increasing trend with increasing heat input for
experiments. heff is no. of effective measured all materials (MS, Al, and Cu).
results defined as [9] • Average heat transfer coefficient of 0.3 and 0.5
୘୭୲ୟ୪ ୣ୶୮ୣ୰୧୫ୣ୬୲ୟ୪ ୲୰୧ୟ୪ୱ
porosity ratios (perforated fin array) are higher
heff = ଵ ା(୲୭୲ୟ୪ ୢୣ୥୰ୣୣ ୭୤ ୤୰ୣୣୢ୭୫ ୭୤ (10) than 0 porosity ratios (non perforated fin array).
୤ୟୡ୲୭୰ୱ ୳ୱୣୢ ୤୭୰ ୮୰ୣୢ୧ୡ୲୧୭୬) • Average heat transfer coefficient of material
The total number of experimental trials are 9, copper of 0.5 porosity ratio is higher than the
with error of variance 0.134, number of same porosity ratio of Material aluminum and
confirmation experiments 3, heff calculated using mild steel as shown in fig.5.
Eqs.(10) which is 1.28.Therefore, the CI is • Percentage improvement in heat transfer
computed to be CI = ±0.820.The confirmation test coefficient due to perforation over non
result are presented in Table 5. The optimal levels perforated fin arrays is given in Table 6.
of corresponding parameters are Porosity at level
III (i.e. 0.5), Heat Input at Level III (i.e. 80W) and Table 6 Improvement in Heat Transfer
Material at Level I (i.e. Cu) for this combination Coefficient over Non Perforated Fin Array
real experimental value of ha is 13.54, which falls
between the predicted confidence interval. Porosity
Copper Aluminum Steel
ratio
0.38 16.09% 14.22% 4.72%
Table 5 Results of confirmation experiment
0.5 46.16% 34.53% 20%
Average heat transfer coefficient (ha)
Confidence
Prediction Real
Interval CI 5. CONCLUSIONS
13.13 ±0.82 13.54
In this study the enhancement of heat transfer
3. Experimental Result and the effect of the various design parameters on
the heat transfer from the flat surface equipped
MS 0.5 with circular perforated fin arrays were
14 AL 0.5 investigated experimentally.
Heat transfer coefficient

CU 0.5 The most important parameter affecting heat

13 AL 0 transfer enhancement is porosity ratio (50.23%
contribution). A perforation in the fin enhances the
W/m^2 K

12 heat transfer and enhancement increases with

11 increase in the porosity ratio for tested range.
Secondly, thermal conductivity also plays an
10 important role for enhancing the heat transfer.
Average heat transfer coefficients of perforated
9 fin arrays of both 0.38 and 0.5 porosity ratio’s are
higher than solid fin arrays (0 porosity ratio) for
8 materials (Cu, Al, MS). Finally one of the most
40 60 80 100 important benefits of utilization of perforated fins
Heat Input Watt (increases porosity ratio) is reduction of fin’s
weight. Low weight certifies saving material of fins
and related equipments such as heat sinks. From
the experimental trials and Taguchi results, new
Fig.5 Variation of Heat Transfer Coefficient
design of fin structure (copper fin with perforation)
against Heat Input of 0.5 Porosity Ratios for can be maximize the rate of heat transfer.
Material MS, Al and Cu and 0 porosity AL

Some important findings from analysis of REFERENCES

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