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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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