Heat Sink Design and Fabrication

Heat Sink Designand FabricationT hermalE ngineeringA nalysisM anufacturing -and- M anagementRyan CondonSteve GehlhausenDavid KeeneTodd MayNathan PiccolaRyan1OutlineProblem DescriptionDesign ProcessMethodologyDesign DescriptionFabricationCalculationsAnalyticalSimulationsExperimentalResultsConclusionRyan2Problem DescriptionCool CPU100 Watts< 90 CMaterialAl 6061-T6Diameter = 4Height = 2AirV = 0.25 6.1 m/sT = 18.3 65.5 CNathan3Design Process Methodology Maximize surface areaKeep cylindricalThin fins and spacingLook at boundary layersDesign for higher air velocitiesNathan4Design Process Design Description22 FinsSpacing = 0.125Width = 0.60Height = 1.5Base = 0.5

Steve5Design Process FabricationTooling LimitationsMany trips wasted timeCostStudent = $710.34Professional = $260.34Environmentally friendly materialHarmfulOilsNon-recyclingSteve6Calculations - AnalyticalChallenging fin propertiesExcel allowed easy changesStepsDefine constantsCalculate RsAdd RsCalculate QsCalculate Ts

Todd7Calculations - SimulationsANSYS IcepakImport SolidWorksEnclosure wind tunnelSet variablesRun simulationPoints to collect data

Todd8Calculations - Simulations

Todd9Calculations - ExperimentalHoles for thermocouplesThermal greaseTapeHighest power -> Lower powerHighest velocity -> Lower velocitySteady state T < 1.0 C / minLabVIEW recorded data

David10Calculations - ExperimentalHeat sink was not mounted flatLimit 56 Watts

David11Results

Todd12ResultsAir velocity = 6.0 m/s

Todd13Results

Power = 32.1 WattsTodd14ConclusionMeets goalsSuggested: 2m/s fanToo Expensive!Unless labor is freeImprovementsMount properlyTest lower velocitiesAdjust ambient temperatureSteve15Questions?Steve16