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Heat Sink Design and Fabrication

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

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  1. 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

  2. Outline • Problem Description • Design Process • Methodology • Design Description • Fabrication • Calculations • Analytical • Simulations • Experimental • Results • Conclusion

  3. 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

  4. Design Process – Methodology • Maximize surface area • Keep cylindrical • Thin fins and spacing • Look at boundary layers • Design for higher air velocities

  5. Design Process – Design Description • 22 Fins • Spacing = 0.125” • Width = 0.60” • Height = 1.5” • Base = 0.5”

  6. Design Process – Fabrication • Tooling Limitations • Many trips wasted time • Cost • Student = $710.34 • Professional = $260.34 • Environmentally friendly material • Harmful • Oils • Non-recycling

  7. Calculations - Analytical • Challenging fin properties • Excel allowed easy changes • Steps • Define constants • Calculate R’s • Add R’s • Calculate Q’s • Calculate T’s

  8. Calculations - Simulations • ANSYS Icepak • Import SolidWorks • Enclosure wind tunnel • Set variables • Run simulation • Points to collect data

  9. Calculations - Simulations

  10. 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

  11. Calculations - Experimental • Heat sink was not mounted flat • Limit 56 Watts

  12. Results

  13. Results Air velocity = 6.0 m/s

  14. Results Power = 32.1 Watts

  15. Conclusion • Meets goals • Suggested: 2m/s fan • Too Expensive! • Unless labor is free • Improvements • Mount properly • Test lower velocities • Adjust ambient temperature

  16. Questions?

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