Body-fitted topology optimization of 2D and 3D fluid-to-fluid heat exchangers

Abstract

We present a topology optimization approach for the design of fluid-to-fluid heat exchangers which rests on an explicit meshed discretization of the phases at stake, at every iteration of the optimization process. The considered physical situations involve a weak coupling between the Navier-Stokes equations for the velocity and the pressure in the fluid, and the convection-diffusion equation for the temperature field. The proposed framework combines several recent techniques from the field of shape and topology optimization, and notably a level-set based mesh evolution algorithm for tracking shapes and their deformations, an efficient optimization algorithm for constrained shape optimization problems, and a numerical method to handle a wide variety of geometric constraints such as thickness constraints and non-penetration constraints. Our strategy is applied to the optimization of various types of heat exchangers. At first, we consider a simplified 2D cross-flow model where the optimized boundary is the section of the hot fluid phase flowing in the transverse direction, which is naturally composed of multiple holes. A minimum thickness constraint is imposed on the cross-section so as to account for manufacturing and maximum pressure drop constraints. In a second part, we optimize the design of 2D and 3D heat exchangers composed of two types of fluid channels (hot and cold), which are separated by a solid body. A non-mixing constraint between the fluid components containing the hot and cold phases is enforced by prescribing a minimum distance between them. Numerical results are presented on a variety of test cases, demonstrating the efficiency of our approach in generating new, realistic, and unconventional heat exchanger designs.

Optimum design and thermal modeling for 2D and 3D natural convection problems incorporating level set‐based topology optimization with body‐fitted mesh

“…Therefore, the surface capturing techniques are highly recommended such as X-FEM 31 and body-fitted adaptive mesh. 52 2. Flow modeling and computational cost.…”

“…However, if this accurate boundary description cannot be converted to the model for the post‐processing, simulation, and manufacturing, the ability of this accurate description makes less sense than it should. Therefore, the surface capturing techniques are highly recommended such as X‐FEM 31 and body‐fitted adaptive mesh 52 Flow modeling and computational cost.…”

Optimal cooling of an internally heated disc

“…How should the fluid flow so that the container cools as quickly as possible? This question arises, for instance, in the design of optimal heat exchangers, whose complicated shapes and flows facilitate heat transfer at rates far beyond diffusion [1][2][3][4][5][6][7][8][9][10]. More generally, the problem is related to the ongoing search for sharp bounds on turbulent heat transfer in a variety of settings, including internally heated [11][12][13][14][15][16] as well as buoyancy-driven convection [17][18][19][20][21], among others.…”

Topology optimization of 3D flow fields for flow batteries

“…Instead, we propose to use topology optimization [52] to computationally guide flow field design. This method has seen significant advancements in recent years, and researchers have used topology optimization to aid in the design of heat exchangers [53,54,55,56,57,58], structural supports [59,60], and microfluidic devices [61,62]. Additionally, topology optimization has been applied to the design of two-dimensional flow fields for both flow batteries [63,64] and fuel cells [65].…”