Heat sink design and fabrication
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Heat Sink Design and Fabrication. Ryan Condon Steve Gehlhausen David Keene Todd May Nathan Piccola. T hermal E ngineering A nalysis M anufacturing -and- M anagement. Outline. Problem Description Design Process Methodology Design Description Fabrication Calculations

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Heat sink design and fabrication

Heat Sink Designand Fabrication

Ryan Condon

Steve Gehlhausen

David Keene

Todd May

Nathan Piccola

T hermal

E ngineering

A nalysis

M anufacturing

-and-

M anagement


Outline
Outline

  • Problem Description

  • Design Process

    • Methodology

    • Design Description

    • Fabrication

  • Calculations

    • Analytical

    • Simulations

    • Experimental

  • Results

  • Conclusion


Problem description
Problem Description

  • Cool CPU

    • 100 Watts

    • < 90 °C

  • Material

    • Al 6061-T6

    • Diameter = 4”

    • Height = 2”

  • Air

    • V = 0.25 – 6.1 m/s

    • T = 18.3 – 65.5 °C


Design process methodology
Design Process – Methodology

  • Maximize surface area

    • Keep cylindrical

    • Thin fins and spacing

  • Look at boundary layers

  • Design for higher air velocities


Design process design description
Design Process – Design Description

  • 22 Fins

    • Spacing = 0.125”

    • Width = 0.60”

  • Height = 1.5”

  • Base = 0.5”


Design process fabrication
Design Process – Fabrication

  • Tooling Limitations

  • Many trips wasted time

  • Cost

    • Student = $710.34

    • Professional = $260.34

  • Environmentally friendly material

  • Harmful

    • Oils

    • Non-recycling


Calculations analytical
Calculations - Analytical

  • Challenging fin properties

  • Excel allowed easy changes

  • Steps

    • Define constants

    • Calculate R’s

    • Add R’s

    • Calculate Q’s

    • Calculate T’s


Calculations simulations
Calculations - Simulations

  • ANSYS Icepak

  • Import SolidWorks

  • Enclosure wind tunnel

  • Set variables

  • Run simulation

  • Points to collect data



Calculations experimental
Calculations - Experimental

  • Holes for thermocouples

  • Thermal grease

  • Tape

  • Highest power -> Lower power

  • Highest velocity -> Lower velocity

  • Steady state T < 1.0 C / min

  • LabVIEW recorded data


Calculations experimental1
Calculations - Experimental

  • Heat sink was not mounted flat

  • Limit 56 Watts



Results1
Results

Air velocity = 6.0 m/s


Results2
Results

Power = 32.1 Watts


Conclusion
Conclusion

  • Meets goals

  • Suggested: 2m/s fan

  • Too Expensive!

    • Unless labor is free

  • Improvements

    • Mount properly

    • Test lower velocities

    • Adjust ambient temperature



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