Friction factor and heat transfer in multiple microchannels with uniform flow distribution

Predictions of flow and heat transfer in microchannels are ongoing issues in microfludics. This work focused on laminar flow (69 < Re < 800) within rectangular microchannel with hydraulic diameter from 106 μm to 307 μm for single-phase liquid flow. The friction factors obtained by experiments on the microchannels showed that conventional theory for fully-developed flow is applicable within the range of our experiments. A manifold configuration which ensured uniform flow through the microchannel array is thought to contribute to the improvement of accuracy. The average Nusselt number for the microchannel array was also evaluated experimentally in the condition of constant heat transfer rate. We found that there were deviations between the experimental and theoretical values of heat transfer rate in the microchannels. In order to predict heat transfer rate accurately, we proposed an empirical correlation in terms of Nu/(Re^0.62 Pr^0.33) and Brinkman number confined to the experimental range. The correlation is expected to be useful to design the microchannel devices related to heat transfer.     

An analytical study of pulsating laminar heat convection in a circular tube with constant heat flux

Pulsating laminar convection heat transfer in a circular tube with constant wall heat flux is investigated analytically. The results show that both the temperature profile and the Nusselt number fluctuate periodically about the solution for steady laminar convection, with the fluctuation amplitude depending on the dimensionless pulsation frequency, ω*, the amplitude, γ, and the Prandtl number, Pr. It is also shown that pulsation has no effect on the time-average Nusselt numbers for pulsating convection heat transfer in a circular tube with constant wall heat flux.     

Combined convection heat transfer for thermally developing aiding flow in an inclined circular cylinder with constant heat flux

Experiments have been conducted to study the local and average heat transfer by mixed convection for hydrodynamically fully developed, thermally developing and thermally fully developed laminar air flow in an inclined circular cylinder. The experimental setup consists of aluminum cylinder as test section with 30 mm inside diameter and 900 mm heated length (L/D = 30), is subjected to a constant wall heat flux boundary condition. The investigation covers Reynolds number range from 400 to 1600, heat flux is varied from 70 W/m² to 400 W/m² and cylinder angles of inclination including 30°, 45° and 60°. The hydrodynamically fully developed condition has been achieved by using aluminum entrance section pipes (calming sections) having the same inside diameter as test section pipe but with variable lengths. The entrance sections included two long calming sections, one with length of 180 cm (L/D = 60), another one with length of 240 cm (L/D = 80) and two short calming sections with lengths of 60 cm (L/D = 20), 120 cm (L/D = 40). The results present the surface temperature distribution along the cylinder length, the local and average Nusselt number distribution with the dimensionless axial distance Z⁺. For all entrance sections, the results showed an increase in the Nusselt number values as the heat flux increases and as the angle of cylinder inclination moves from θ = 60° inclined cylinder to θ = 0° horizontal cylinder. The mixed convection regime has been bounded by the convenient selection of Re number range and the heat flux range, so that the obtained Richardson numbers (Ri) is varied approximately from 0.13 to 7.125. The average Nusselt numbers have been correlated with the (Rayleigh numbers/Reynolds numbers) in empirical correlations.     

Numerical study of the hydrodynamics and heat transfer characteristics of liquid–liquid Taylor flow in microchannel

A numerical study of an oil–water Taylor flow is presented in this paper to explore its flow and heat transfer characteristics. Due to the large surface area to volume ratio in narrow channels, using slug flows, high heat and mass transfer rates could be achieved. Sound knowledge of the underlying physics of slug flow is required for the practical design of microfluidic devices. In this study, hydrodynamics and heat transfer characteristics of dispersed oil droplets flowing inside a vertically upward circular microchannel (D = 0.1 mm) with water being the carrier phase have been explored numerically. ANSYS Fluent was employed to capture the liquid–liquid interface using volume of fluid method. Two different boundary conditions were considered in the present study. First, an isothermal wall of 373 K and later a constant wall heat flux (420 kW/m²) were, respectively, prescribed over the wall of the microchannel. The numerical code was validated against the results available in the literature, and the significant results in the form of pressure drop and heat transfer rates have been discussed. A considerable increase in Nusselt number, up to 180% and 210%, was observed with the oil–water slug flow in contrast to the liquid‐only single‐phase flow inside the microchannel for isothermal and constant wall heat flux conditions, respectively.     

Thermally developing flow and heat transfer in rectangular microchannels of different aspect ratios

Laminar convective heat transfer in the entrance region of microchannels of rectangular cross-section is investigated under circumferentially uniform wall temperature and axially uniform wall heat flux thermal boundary conditions. Three-dimensional numerical simulations were performed for laminar thermally developing flow in microchannels of different aspect ratios. Based on the temperature and heat flux distributions obtained, both the local and average Nusselt numbers are presented graphically as a function of the dimensionless axial distance and channel aspect ratio. Generalized correlations, useful for the design and optimization of microchannel heat sinks and other microfluidic devices, are proposed for predicting Nusselt numbers. The proposed correlations are compared with other conventional correlations and with available experimental data, and show very good agreement.     

Experimental investigation of mixed convection heat transfer for thermally developing flow in a horizontal circular cylinder

An experimental investigation is presented on mixed (free and forced) convection to study the local and average heat transfer for hydrodynamically fully developed, thermally developing and thermally fully developed laminar air flow in a horizontal circular cylinder. The experimental setup consists of aluminum cylinder as test section with 30 mm inside diameter and 900 mm heated length (L/D = 30), is subjected to a constant wall heat flux boundary condition. The investigation covers Reynolds number range from 400 to 1600, the heat flux varied from 60 W/m² to 400 W/m² and with cylinder inclination angle of θ = 0° (horizontal). The hydrodynamically fully developed condition is achieved by using an aluminum entrance section pipes (calming sections) having the same inside diameter as test section pipe but with variable lengths. The entrance sections included two long calming sections, one with length of 180 cm (L/D = 60), another one with length of 240 cm (L/D = 80) and two short calming sections with lengths 60 cm (L/D = 20), 120 cm (L/D = 40). The surface temperature variation along the cylinder surface, the local and average Nusselt number variation with the dimensionless axial distance Z⁺ were presented. For all entrance sections, it was found an increase in the Nusselt number values as the heat flux increases. It was concluded that the free convection effects tended to decrease the heat transfer results at low Re while to increase the heat transfer results for high Re. The combined convection regime could be bounded by a suitable selection of Re number ranges and the heat flux ranges. The obtained Richardson numbers (Ri) range varied approximately from 0.13 to 7.125. The average Nusselt numbers were correlated with the (Rayleigh numbers/Reynolds numbers). The proposed correlation has been compared with available literature and showed satisfactory agreement.     

Bias effects on heat transfer measurements in microchannel flows

This work is devoted to both experimental and numerical investigations of the hydrodynamics and associated heat transfer in two-dimensional microchannels from 700 μm to 200 μm in height. The design of the test section enabled to vary the channel height and to set a quasi-constant heat flux at the microchannel surface. Laminar developing, transitional and turbulent regimes of water flows were explored (200 < Re < 8000). A significant decrease in the Nusselt number was observed in the laminar regime when the channel spacing was decreased while the Poiseuille number remained unchanged in regard to conventional channel flow. It is shown that a bias effect in the solid/fluid interface temperature measurements is most likely responsible for this scale effect. The temperature error was estimated and accounted for in the determination of the Nusselt number. The corrected values have been found to be consistent with the conventional laws both in the laminar and in the beginning of the turbulent regime.     

Experimental study of forced and free convective heat transfer in the thermal entry region of horizontal concentric annuli

Forced and free convective heat transfer for thermally developing and thermally fully developed laminar air flow inside horizontal concentric annuli in the thermal entrance length has been experimentally investigated. The experimental setup consists of a stainless steel annulus having a radius ratio of 2 and an inner tube with a heated length of 900 mm subjected to a constant wall heat flux boundary condition and an adiabatic outer annulus. The investigation covers Reynolds number range from 200 to 1000, the Grashof number was ranged from 6.2 × 10⁵ to 1.2 × 10⁷. The entrance sections used were long tube with length of 2520 mm (L/D_h = 63) and short tube with length of 504 mm (L/D_h = 12.6). The surface temperature distribution along the inner tube surface, and the local Nusselt number distribution versus dimensionless axial distance Z_t were presented and discussed. It is inferred that the free convection effects tended to decrease the heat transfer at low Re number while to increase the heat transfer for high Re number. This investigation reveals that the Nusselt number values were considerably greater than the corresponding values for fully developed combined convection over a significant portion of the annulus. The average heat transfer results were correlated in terms of the relevant dimensionless variables with an empirical correlation. The local Nusselt number results were compared with available literature and show similar trend and satisfactory agreement.     

Three-dimensional laminar flow and heat transfer in a parallel array of microchannels etched on a substrate

Heat transfer and laminar fluid flow in an array of parallel microchannels etched on a silicon substrate with water as the circulating fluid was studied numerically. The fluid region consisted of a microchannel with a hydraulic diameter of 85.6 μm and aspect ratios ranging from 0.10 to 1.0. A constant heat flux of 90 W/cm² was applied to the y = H face of the computational domain, which simulates thermal energy generation from an integrated circuit. Generalized transport equations were discretized and solved in three dimensions for velocities, pressure, and temperature. The SIMPLE algorithm [S.V. Patankar, Numerical Heat Transfer and Fluid Flow, Hemisphere, New York, 1980] was used to link pressure and velocity fields, and a thermally repeated boundary condition was applied in the lateral direction to model the repeating nature of the geometry. The numerical results for apparent friction coefficient and convective thermal resistance at the channel inlet and exit closely matched the experimental data in the literature for the case of 0.32 aspect ratio. Apparent friction coefficients were found to increase linearly with Reynolds number. Inlet and outlet thermal resistance values monotonically decreased with increasing Reynolds number and increased with aspect ratio.     

An experimental and numerical study of forced convection in a microchannel with negligible axial heat conduction

Experiments are conducted for laminar forced convection of water in a microchannel under partially-heated and fully-heated conditions on one wall with negligible axial heat conduction. The microchannel had a trapezoidal cross-sectional shape, with a hydraulic diameter of 155 μm and a heating length of 30 mm. Three-dimensional numerical simulations, based on the Navier–Stokes equations and energy equation, are obtained for forced convection of water in this microchannel under the same experimental conditions. It is found that the numerical predictions of wall temperatures and local Nusselt numbers are in good agreement with experimental data. This confirms that classical Navier–Stokes and energy equations are valid for the modeling of convection in a microchannel having a hydraulic diameter as small as 155 μm. For a microchannel with the same cross-sectional shape with one-wall heated and a heating length of 100 mm, numerical results show that the thermal entrance length is given by z = 0.15RePrD_h, with the fully-developed Nusselt number approaching a constant value of 4.00.     

Study of the heat transfer characteristics in turbulent combined wall and offset jet flows

The heat transfer study of a combined wall jet and offset jet flow with different wall jet and offset jet flow velocities are considered. The flow is considered two-dimensional, steady, incompressible, turbulent at high Reynolds number with negligible body forces. The streamline curvature modification of the standard k–ε model is used to carry out the turbulence modeling. The Reynolds number is varied from 10⁴ to 4 × 10⁴ and Pr = 0.71 is taken for all computations. Constant wall temperature and constant wall heat flux boundary conditions are considered. The results are presented in the form of local Nusselt number, local heat flux, surface temperature in case of constant heat flux condition, average Nusselt number and total heat transfer.     

Analysis of laminar heat transfer in micro-Poiseuille flow

The present study examines laminar forced convective heat transfer of a Newtonian fluid in a microchannel between two parallel plates analytically. The viscous dissipation effect, the velocity slip and the temperature jump at the wall are included in the analysis. Both hydrodynamically and thermally fully developed flow case is examined. Either the hot wall or the cold wall case is considered for the two different thermal boundary conditions, namely the constant heat flux (CHF) and the constant wall temperature (CWT). The interactive effects of the Brinkman number and the Knudsen number on the Nusselt numbers are analytically determined. Different definitions of the Brinkman number based on the definition of the dimensionless temperature are discussed. It is disclosed that for the cases studied here, singularities for the Brinkman number-dependence of the Nusselt number are observed and they are discussed in view of the energy balance.     

Effects of viscous dissipation on the heat transfer in a forced pipe flow. Part 2: Thermally developing flow

In this part of the study, consideration is given to thermally developing laminar forced convection in a pipe including viscous dissipation. The axial heat conduction in the fluid is neglected. Two different thermal boundary conditions are considered: the constant heat flux (CHF) and the constant wall temperature (CWT). Both the wall heating (the fluid is heated) case and the wall cooling (the fluid is cooled) case are considered. The distributions for the developing temperature and local Nusselt number in the entrance region are obtained. Results show that the temperature profiles and local Nusselt number are influenced by the Brinkman number (Br) and the thermal boundary condition used for the wall. Significant viscous dissipation effects have been observed for large Br.     

An experimental study of convective heat transfer in silicon microchannels with different surface conditions

An experimental investigation has been performed on the laminar convective heat transfer and pressure drop of water in 13 different trapezoidal silicon microchannels. It is found that the values of Nusselt number and apparent friction constant depend greatly on different geometric parameters. The laminar Nusselt number and apparent friction constant increase with the increase of surface roughness and surface hydrophilic property. These increases become more obvious at larger Reynolds numbers. The experimental results also show that the Nusselt number increases almost linearly with the Reynolds number at low Reynolds numbers (Re<100), but increases slowly at a Reynolds number greater than 100. Based on 168 experimental data points, dimensionless correlations for the Nusselt number and the apparent friction constant are obtained for the flow of water in trapezoidal microchannels having different geometric parameters, surface roughnesses and surface hydrophilic properties. Finally, an evaluation of heat flux per pumping power and per temperature difference is given for the microchannels used in this experiment.     

Analysis of microchannel heat sinks for electronics cooling

This paper presents an analytical and numerical study on the heat transfer characteristics of forced convection across a microchannel heat sink. Two analytical approaches are used: the porous medium model and the fin approach. In the porous medium approach, the modified Darcy equation for the fluid and the two-equation model for heat transfer between the solid and fluid phases are employed. Firstly, the effects of channel aspect ratio (α_s) and effective thermal conductivity ratio (k?) on the overall Nusselt number of the heat sink are studied in detail. The predictions from the two approaches both show that the overall Nusselt number (Nu) increases as α_s is increased and decreases with increasing k?. However, the results also reveal that there exists significant difference between the two approaches for both the temperature distributions and overall Nusselt numbers, and the discrepancy becomes larger as either α_s or k? is increased. It is suggested that this discrepancy can be attributed to the indispensable assumption of uniform fluid temperature in the direction normal to the coolant flow invoked in the fin approach. The effect of porosity (ε) on the thermal performance of the microchannel is subsequently examined. It is found that whereas the porous medium model predicts the existence of an optimal porosity for the microchannel heat sink, the fin approach predicts that the heat transfer capability of the heat sink increases monotonically with the porosity. The effect of turbulent heat transfer within the microchannel is next studied, and it is found that turbulent heat transfer results in a decreased optimal porosity in comparison with that for the laminar flow. A new concept of microchannel cooling in combination with microheat pipes is proposed, and the enhancement in heat transfer due to the heat pipes is estimated. Finally, two-dimensional numerical calculations are conducted for both constant heat flux and constant wall temperature conditions to check the accuracy of analytical solutions and to examine the effect of different boundary conditions on the overall heat transfer.     

Constructal design and thermal analysis of microchannel heat sinks with multistage bifurcations in single-phase liquid flow

Based on constructal theory, five different cases with multistage bifurcations are designed as well as one case without bifurcations, and the corresponding laminar fluid flow and thermal performance have been investigated numerically. All laminar fluid flow and heat transfer results are obtained using computation fluid dynamics, and a uniform wall heat flux thermal boundary condition is applied all heated surfaces. The inlet velocity ranges from 0.66 m/s to 1.6 m/s with the corresponding Reynolds number ranging from 230 to 560. The pressure, velocity, temperature distributions and averaged Nusselt number are presented. The overall thermal resistances versus inlet Reynolds number or pumping power are evaluated and compared for the six microchannel heat sinks. Numerical results show that the thermal performance of the microchannel heat sink with multistage bifurcation flow is better than that of the corresponding straight microchannel heat sink. The heat sink with a long bifurcation length in the first stage (Case 1A) is superior. The usage of multistage bifurcated plates in microchannel heat sink can reduce the overall thermal resistance and make the temperature of the heated surface more uniform (Case 3). It is suggested that proper design of the multistage bifurcations could be employed to improve the overall thermal performance of microchannel heat sinks and the maximum number of stages of bifurcations is recommended to be two. The study complements and extends previous works.     

Steady forced convection heat transfer from a heated circular cylinder to power-law fluids

Forced convection heat transfer to incompressible power-law fluids from a heated circular cylinder in the steady cross-flow regime has been investigated numerically by solving the momentum and thermal energy equations using a finite volume method and the QUICK scheme on a non-uniform Cartesian grid. The dependence of the average Nusselt number on the Reynolds number (5 ⩽ Re ⩽ 40), power-law index (0.6 ⩽ n ⩽ 2) and Prandtl number (1 ⩽ Pr ⩽ 1000) has been studied in detail. The numerical results are used to develop simple correlations as functions of the pertinent dimensionless variables. In addition to the average Nusselt number, the effects of Re, Pr and n on the local Nusselt number distribution have also been studied to provide further physical insights. The role of the two types of thermal boundary conditions, namely, constant temperature and uniform heat flux on the surface of the cylinder has also been presented.     

Similarity solutions for flows and heat transfer in microchannels between two parallel plates

In this paper we give analytical similarity solutions of the Navier–Stokes equations coupled with energy equation of Newtonian fluid in a microchannel between two parallel plates taking into account the effects of viscous dissipation, the velocity slip and the temperature jump at the wall. Two different thermal boundary conditions are considered: the constant heat flux (CHF) and the constant wall temperature (CWT). We provide new similarity transformations for the governing equations and derive the expressions of Poiseuille number (Po) and Nusselt number (Nu). Then, the homotopy analysis method (HAM) is employed to solve the nonlinear differential equations with related boundary conditions. Both the dimensionless analytical expressions of velocity and temperature are obtained. The rarefaction effects on velocity distribution and flow friction are exhibited. The interactive effects of the Brinkman number (Br) and the Knudsen number (Kn) on Nu are analytically studied for both the CHF and CWT cases.     

Estimation of heat transfer coefficients in oscillating flows: The thermoacoustic case

The classical linear thermoacoustic theory is integrated through a numerical calculus with a simple energy conservation model to allow estimates of the optimal length of thermoacoustic heat exchangers and of the magnitude of the related heat transfer coefficients between gas and solid walls. This information results from the analysis of the temperature and heat flux density distributions inside a thermally isolated thermoacoustic stack. The effects of acoustic amplitude, plate spacing, plate thickness and Reynolds number on the heat transfer characteristics are examined. The results indicate that a net heat exchange between the acoustically oscillating gas and the solid boundary takes place only within a limited distance from the stack edges. This distance is found to be an increasing function of the plate spacing in the range (0 ⩽ y₀/δ_κ ⩽ 2), becoming constant for y₀/δ_κ ⩾ 2. The calculated dimensionless convective heat transfer coefficients, the Nusselt numbers, between gas and solid wall are comparable to those evaluated from classical correlations for steady laminar flow revised under the “Time-Average Steady-Flow Equivalent” (TASFE) and “root-mean-square Reynolds number” (RMSRe) models. Numerical results agree with measurements of the heat transfer coefficient found in literature to within 20%.     

Can segmented flow enhance heat transfer in microchannel heat sinks?

Liquid cooling is an efficient way to remove heat fluxes with magnitudes up to 10,000 W/cm². One limitation of current single-phase microchannel heat sinks is the relatively low Nusselt number, due to laminar flow. In this work, we experimentally investigate how to enhance the Nusselt number with the introduction of segmented flow. The segmented flow pattern was created by the periodic injection of air bubbles through a T-junction into water-filled channels. We designed a polycarbonate heat sink consisting of an array of seven parallel microchannels each with a square cross-section 500 μm wide. We show that segmented flow increases the Nusselt number of laminar flow by more than 100%, provided the mass velocity of the liquid is within the range 330–2000 kg/m² s.