Exploration of a Hybrid Analytical Thermal Topology Optimization Method for an Additively Manufactured Heat Sink

While Additive Manufacturing(AM) fabricated parts are finding their parts to more and more applications, some tools for designing for an “additive future” are still in development. Conjugate heat transfer thermal topology optimization remains a subject of research due to the complex nature of evolving geometry and boundary layer heat transfer. This study presents a Hybrid Analytical Thermal Topology Optimization(HATTO) approach, wherein the solid geometry is optimized in discrete fashion with an analytical boundary layer heat transfer profile mapped on the exterior surface. A finite volume model is presented that removes cells at each iteration to reach a specified objective. The HATTO method proved effective at reaching a target of 50% mass reduction of a single fin while maximizing heat rejection at each iteration with a laminar flow streamwise varying heat transfer boundary condition. The resulting geometry morphed into a shape similar but slightly superior to the anticipated shortened fin solution. Although limited to simple topology, it is anticipated that the principle of HATTO can be applied to a variety of different cases, flow solutions and geometries giving thermal designers a simplified method for conjugate heat transfer optimization.