Improving the accuracy of the topology optimization of turbulent flows

Improving the accuracy of the topology optimization of turbulent flows

Krol, Robert (TU Delft Mechanical, Maritime and Materials Engineering; TU Delft Precision and Microsystems Engineering)

Langelaar, Matthijs (mentor)
Theulings, M.J.B. (mentor)
Hoeven, Frank (graduation committee)
van der Hout, Thomas (graduation committee)
Pourquie, M.J.B.M. (graduation committee)
Noel, L.F.P. (graduation committee)

Delft University of Technology

Mechanical Engineering

2023-02-23

Silicon based power semiconductors have long been used as the standard in ‘semiconductor technology in power conversion applications’. Recent developments replaces the Silicon with Silicon Carbide as it results in superior performance of the power conversion applications. However, due to the increased performance, challenges regarding heat dissipation emerge and the lifetime of the power semiconductor packaging or power module is compromised. Since this leads to an increase power density, the cooling of the power module is becoming of more importance and the heat sink becomes an interesting component to optimize. The best performance of a heat sink can be obtained when the flow through the device is turbulent. Developing turbulent flow heat sinks by using topology optimization methods can significantly improve the cooling performance compared to the current designs. This work is thus aimed towards improving methods for topology optimization of turbulent flow cooling devices. However, this work focuses on turbulent flow topology optimization only and aims to improve the accuracy of current methods. It is important that the flow physics are accurate since the thermal energy transfer is dependent on the flow field. The current state-of-the-art method based on the 𝑘−𝜔 turbulence model developed by Dilgen et al. is investigated. A design domain is subdivided into elements since the finite element method (FEM) is used, such that an optimization algorithm is able to turn every element into either fluid or solid with the goal of finding the best performing structure. This density based approach, models the solid domain as a highly impermeably porous material. To inhibit flow in the solid domain a Darcy penalization is added to the momentum equation. Moreover, in the method by Dilgen et al. boundary conditions in the other turbulent fields are also enforced using a similar penalization approach. Weaknesses and errors in the density based method are investigated by comparing solutions to ones computed on a body fitted mesh. It has been found that the largest errors in the solution, by using the state-of-the-art method, appear at the solid/fluid interface in the design. In these regions the penalizations are not applied correctly for the desired boundary conditions. Therefore, in this work it is improved on by the enforcement of the boundary condition by using the Dilation method. The Dilation method focuses on the solid/fluid region where it shifts the boundary conditions for the specific dissipation rate (𝜔) and ensures it reaches the desired value at the solid/fluid interface. Secondly, severe flow leakage is found in the “porous” solid domains using the state-of-the-art method. Flow leakage is reduced by using an improved formulation of the maximum Darcy penalization in the solid domain. Finally, the improved approach is investigated in several topology optimization cases and compared to the state-of-the-art Dilgen method. It is shown that by using the new approach, different designs with a better accuracy can be obtained. In an extreme test case, the Dilgen method resulted in an infeasible design which disconnects the flow inlets from the outlets while the new and improved method resulted in a feasible design.

Topology optimization
Density-based method
Fluid flow
Turbulence
Computational Fluid Dynamics (CFD)

http://resolver.tudelft.nl/uuid:de1a468a-739c-4051-953c-0555f16bf773

2024-02-23

Student theses

master thesis

© 2023 Robert Krol