Topology optimization and performance research of microchannel heat exchangers

doi:10.11949/0438-1157.20231236

Abstract

Abstract:

The structure topology optimization of the heat exchanger transforms the design problem of enhancing heat transfer into a mathematical optimization problem, which is important in finding novel design for high performance heat exchanger. However, it is difficult for the topology optimization mathematical model to directly explain the geometric characteristics of the optimization results and the corresponding strengthening mechanism. The topology optimization design is conducted for the heat transfer enhancement of microchannel heat exchanger. The impacts of different factors on the optimized structures and heat transfer performance are investigated. The optimization results show that the channels of the topology-optimized heat exchanger present a “hierarchical bifurcation” configuration, and the number of bifurcations increases with the increase of the inlet Reynolds number, the vertical heat transfer of fins, and the Prandtl number of liquid. Based on these findings, entransy dissipation theory and boundary layer theory are applied to reveal the mechanism of heat transfer enhancement, which provided new ideas for the structural strengthening design of the heat exchanger.

Key words: optimal design, microchannel, transport processes, hierarchical channel pattern, boundary layer theory

摘要：

换热器结构拓扑优化可将传热强化设计问题转化为数学优化问题进行求解，对于设计新颖高效换热器具有重要价值。然而，拓扑优化数学模型难以直接解释优化结果的几何特征及相应强化机理。以传热量为目标，对微通道换热器进行拓扑优化设计，研究了不同参数对换热器强化结构特征和换热器性能的影响。结果表明，拓扑优化换热器的通道结构呈现多级分叉构型，分叉的数量随着入口Reynolds数、翅片传热效率和流体Prandtl数的增大而增多。在此基础上，采用耗散和边界层理论分析了拓扑优化分叉通道与流体边界层厚度的内在联系，为换热器结构强化设计提供了新的思路。

关键词: 优化设计, 微通道, 传递过程, 分级通道结构, 边界层理论

CLC Number:

TK 124

Yansong CHEN, Da RUAN, Yuanbo LIU, Tong ZHENG, Shuaishuai ZHANG, Xuehu MA. Topology optimization and performance research of microchannel heat exchangers[J]. CIESC Journal, 2024, 75(3): 823-835.

陈彦松, 阮达, 刘渊博, 郑通, 张帅帅, 马学虎. 微通道换热器拓扑结构优化与性能研究[J]. 化工学报, 2024, 75(3): 823-835.

Figures/Tables 10

Fig.1 Heat exchanger model

Table 1 Parameters for different cases

案例编号	$Δ p$ /Pa	$h z$ /(W/(m²·K))
组Ⅰ(1~10)	1~10	$103$
组Ⅱ(1~10)	1~10	$5 × 103$
组Ⅲ(1~10)	1~10	$104$
组Ⅳ(1~10)	1~10	$5 × 104$

Table 1 Parameters for different cases

案例编号	$Δ p$ /Pa	$h z$ /(W/(m²·K))
组Ⅰ(1~10)	1~10	$103$
组Ⅱ(1~10)	1~10	$5 × 103$
组Ⅲ(1~10)	1~10	$104$
组Ⅳ(1~10)	1~10	$5 × 104$

Fig.2 Topology optimization results under different pressure drop conditions

Fig.3 The optimization results for different cases

Fig.4 Plot of dimensionless pressure drop Δp˜versusRein

Table 2 Physical parameters and boundary conditions for different fluid media

物质名称	动力黏度 $μ$ /(Pa·s)	密度 $ρ$ /(kg/m³)	热导率 $k l$ /(W/(m·K))	比等压热容 $c p, l$ /(J/(kg·K))	$P r$	$R e i n$	入口压力/Pa
液态金属	0.0024	6440	16.5	200	0.029	996.9	9.085
水	0.0010	998	0.600	4180	6.99	1000.0	10.24
FC40 (3M)	0.0041	1855	0.065	1100	69.4	997.8	92.05
乙二醇	0.0214	1116.5	0.2495	2383	204.6	995.8	4172

Table 2 Physical parameters and boundary conditions for different fluid media

物质名称	动力黏度 $μ$ /(Pa·s)	密度 $ρ$ /(kg/m³)	热导率 $k l$ /(W/(m·K))	比等压热容 $c p, l$ /(J/(kg·K))	$P r$	$R e i n$	入口压力/Pa
液态金属	0.0024	6440	16.5	200	0.029	996.9	9.085
水	0.0010	998	0.600	4180	6.99	1000.0	10.24
FC40 (3M)	0.0041	1855	0.065	1100	69.4	997.8	92.05
乙二醇	0.0214	1116.5	0.2495	2383	204.6	995.8	4172

Fig.5 Distribution diagram of solid-liquid region (γ) for topological optimization of different working fluids

Fig.6 Boundary layer regions corresponding to different Pr and field synergy relations

Fig.7 Geometrical sketch of typical wedge structures in topology optimized heat exchanger

Table 3 Critical values of η of flow and heat transfer boundary layer at fully developed conditions for different wedge angles

$β / (°)$	$η U$	$η t P r = 0.029$	$η t P r = 6.99$	$η t P r = 69.4$	$η t P r = 204.6$
$-$ 30	6.11	24.19	3.08	1.51	1.08
$-$ 20	5.56	23.58	2.76	1.31	0.93
$-$ 10	5.20	23.10	2.58	1.20	0.85
0	4.91	22.66	2.45	1.13	0.78
20	4.46	21.88	2.26	1.03	0.72
40	4.09	21.12	2.12	0.95	0.66
60	3.78	20.38	1.99	0.89	0.62
80	3.50	19.63	1.88	0.84	0.58
90	3.37	19.25	1.83	0.81	0.56
100	3.25	18.87	1.78	0.78	0.54
120	3.01	18.10	1.68	0.73	0.51
140	2.79	17.30	1.59	0.69	0.48

Table 3 Critical values of η of flow and heat transfer boundary layer at fully developed conditions for different wedge angles

$β / (°)$	$η U$	$η t P r = 0.029$	$η t P r = 6.99$	$η t P r = 69.4$	$η t P r = 204.6$
$-$ 30	6.11	24.19	3.08	1.51	1.08
$-$ 20	5.56	23.58	2.76	1.31	0.93
$-$ 10	5.20	23.10	2.58	1.20	0.85
0	4.91	22.66	2.45	1.13	0.78
20	4.46	21.88	2.26	1.03	0.72
40	4.09	21.12	2.12	0.95	0.66
60	3.78	20.38	1.99	0.89	0.62
80	3.50	19.63	1.88	0.84	0.58
90	3.37	19.25	1.83	0.81	0.56
100	3.25	18.87	1.78	0.78	0.54
120	3.01	18.10	1.68	0.73	0.51
140	2.79	17.30	1.59	0.69	0.48

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