Fluent-Intro 15.0 WS06 Electronics Cooling Plus EKM Rev2

© 2014 ANSYS, Inc. February 28, 2014 1 Release 15.0

15.0 Release

Introduction to ANSYS Fluent

Workshop 06 Electronics Cooling with Natural Convection and Radiation


Workshop Description: • In this workshop you will model the heat dissipation from a hot electronics

component fitted to a printed circuit board (PCB). Heat is dissipated via a finned heat sink

Learning Aims: • This workshop introduces ways in which heat transfer can be incorporated within a

simulation. The processes include: - Thermal conduction in solids - Modelling thermal radiation - Natural convection of the heated air - Conjugate heat transfer

Learning Objectives: • To understand how different forms of heat transfer can be incorporated within a

CFD simulation (including using CFD to solve for thermal conduction in solid materials)

Introduction Basic Model Setup Radiation Model Setup Solving Post-Processing Summary

Introduction


It is strongly recommended to use double precision not only in this workshop but in all heat transfer calculations in Fluent. This helps to achieve a tighter energy balance and helps the solver to converge in fewer iterations than would be required in the same case with single precision.

Before Starting


Mesh Import (Workbench)

This workshop can be done either inside or outside of ANSYS Workbench.

If working with Fluent within Workbench

Open a new Workbench session and select a new Fluent session from Component Systems

In the WB Menu bar, select View > Properties and choose Double Precision

Use Save As to save the session

Import the mesh file. • Right-click on the Setup cell • Click on “Import Fluent Case” • Change Files of Type to Fluent

Mesh File • Select the mesh file heatsink.msh • Click Open

Launch Fluent using the default options

Drag



Mesh Import (Stand-alone)

Start a 3D, double precision Fluent session from the icon or from the Windows Start menu

Select either

– File > Read > Mesh from the top menu

– Open File icon from toolbar and select mesh

Open the file heatsink.msh

If working with Fluent Standalone



View the model

Check the mesh (from General tab). • Review the text in the lower Fluent window and

check there are no errors

Display the mesh and adjust the display settings • Under Graphics and Animations select Mesh

• Set Faces to on, and Edges to ‘Feature’

• Deselect all currently selected faces

• Select Surface Types Pressure Outlet, Velocity Inlet and Wall (note effect on Surfaces list)

• Select Colors

• Color by ID

• Close

• Click Display

Display Lights and turn on the headlight



Model setup

Change Temperature Units to °C

• Define Units

• Select Temperature as a Quantity

• Select “c” as the temperature units

• Close the panel

Enable the Energy Equation

• Select the Models Tree Item

• Double-click on Energy and enable the equation

OR

• Click on Energy and then Edit



Comments on Model setup • It is good practice to display the grid after import to check for any errors in boundary

zone assignments and that you have opened the correct model

• Workbench uses SI units (metres, kg etc) but if importing a mesh from another source check the scale and dimensions are correct

• Check mesh is used to confirm the mesh is suitable for use in a CFD simulation

• Report Quality is a backup to the quality tools available within the meshing application

By default the energy equation is not active when the mesh is first loaded, because many problems are isothermal. In this case, temperature must be calculated so the energy equation needs to be enabled.

The onset of turbulence is specified by the Reynolds Number (pipe flow) or Rayleigh Number (natural convection). Calculating these numbers for this geometry and conditions indicates that the flow will be laminar and so no change is required to the viscous model.



Material properties The air density needs to change with temperature (but not pressure)

• Select Materials > Air > Create/Edit

– Change density to incompressible ideal gas

– All other properties remain unchanged

– Click Change/ Create

– Close the Create/Edit Materials Window

Define three additional Solid Materials (for the Board, Heat Sink and Heat Source) • Select Materials Solid Create/Edit

• Click the Fluent Database button.

• Change Type to Solid

• Select Copper

• Copy then close the database window



Material properties Modify the Copper Material to produce the PCB Material

• The PCB is made of Material “FR-4”

– Change Name from copper to fr-4

– Delete the chemical formula

– Density = 1250kg/m3; cp = 1300 J/kg K; conductivity 0.35 W/m K

– Click Change/Create

• Click No when prompted to overwrite copper

Again, modify the Copper Material to create the a new material called “component” using the same steps as above

• Density = 1900 kg/m3; cp = 795 J/kg K; Thermal Conductivity = 10 W/m K

Selecting No will create a new material fr-4, but copper remains in the material list. Selecting Yes would overwrite the copper material for the current case only (it’s still in the database).



Comments on Material properties

In most natural convection problems the change of density with temperature drives the flow. The changes in pressure over the domain are minimal, and their effect on density negligible, hence the incompressible ideal gas density formulation can be used instead of the fully compressible ideal gas model.

The Fluent database contains basic properties for many materials. These are generally set to the standard STP/RTP values, but always check these are suitable before proceeding.

Additional materials can be added to the database; refer to the user documentation. It is often easier to copy a material from the database and then modify it; alternatively, you can modify the default material of aluminium and then choose not to overwrite.



Set Cell Zone Conditions Under Cell Zone Conditions click the Operating Conditions Button

• Enable Gravity, and set the Y Component to -9.81 m/s2

• Turn on Specified Operating Density and set to 1.11 kg/m3

• Click OK

There are no changes to the fluid zone

• Cell Zone > Fluid > Edit

• Observe that this contains Material Air which is correct.

• Close the Window



Set Cell Zone Conditions

Set the material properties for the PCB:

• Select Cell Zone solid_board, and Edit

– Change the material to fr-4

– OK to close the window

Set the material properties for the heat sink - Heatsink is made of copper:

• Select the cell zone solid_heatsink

• Change the material to copper



Set Cell Zone Conditions

Set the Conditions for the Component:

• We need to set both the material AND the thermal power (75W) dissipated by this component

• Select zone solid_heatsource

• Change the Material to component

• Check Source Terms then go to the Source Terms tab

• The component Volume is 0.11808x10-3 m3. Hence, the volumetric source is 635000 W/m3

• Create one constant Energy Source with the above value



Set Boundary Conditions

For the Inlet (Boundary Conditions > Inlet):

• Change type to Pressure Inlet

• Keep the pressure at 0 Pa

• Under the Thermal tab set the temperature to 45 °C, then OK

For the Outlet:

• Keep type as Pressure Outlet

• Set 0 Pa Gauge Pressure

• Change Direction to “From Neighbouring Cell”

• Under the Thermal tab set Backflow Total Temperature to 45°C, then OK



Set Boundary Conditions Set the casing walls to be adiabatic:

• Select boundary zone wall_left

• Under the thermal tab, check this is set to zero heat flux

• Repeat for wall_right and wall_top

Set the PCB outer surface thermal properties to be adiabatic:

• These are the external surfaces of the model

• The surfaces to set are wall_board_bottom and wall_board_side

• Set these to zero heat flux as above

Note that the surface wall_board is the surface of the PCB that is adjacent to the fluid air region, and so is not an exterior boundary.



Comments on Cell and Zone Conditions

Operating conditions

• Gravity is required for natural convection. In many cases there are no gravity effects, and the option can remain inactive

• Operating density is critical in natural convection problems, and should be set to the density at the far field temperature (i.e. inlet temperature)

• Operating pressure position is related to the inlet/outlet pressure settings. In this example, it is positioned at the inlet

Boundary zones

• Inlet and Outlet pressure are set to 0 Pa gauge




Volume data:

• The volume of an entity can be reported from the Volume Integrals panel. Note that the solution must be initialized before the volume integrals are enabled

External heat loss:

• Here, adiabatic conditions have been set for the external walls.

• However if needed, Fluent can model an external boundary in several different ways, including:

– Known heat flux (W/m2)

– Known heat transfer coefficient (eg for natural convection from a vertical plate)

– Heat transfer through radiation (by setting emissivity and temperature). Note this is not related to radiation models available within Fluent

– Shell conduction in the outer wall (hence fields for material and wall thickness)




Interior boundaries:

• In this example, there are four cell zones; including fluid and solid_board

• Just one label wall_board was created at the pre-processing stage for the surface common to these two zones

• When loading the mesh, Fluent creates a clone: wall_board_shadow

• Open up the boundary conditions for these surfaces and observe that:

– wall_board has the adjacent cell zone fluid

– wall_board_shadow has the adjacent cell zone solid_board

• If setting emissivity or roughness, make sure the correct face is selected!



Introduction Model Setup Solving Post-Processing Summary

Create a Monitoring Point • Create a point surface, to be used to monitor the air temperature a short

distance above the component

– In the menu bar across the top of the panel, select Surface -> Point

– Enter the coordinates (in meters) (0,0.15,0.05) and click Create

– Go to Display > Mesh, select the point and verify its location



Surface Monitor • In ‘Monitors’, press ‘Create...’ for a Surface Monitor

– Enter ‘air-temp-mon’ for the name

– Check the box to Plot and set the window number to 2

– Choose Vertex Average for the report type

– Choose Static Temperature for the variable

– Select point-21 as the surface

– Click OK and then OK again

Fluent can only monitor temperatures in Kelvin or Rankine. This applies only to the surface monitor and does not affect the units you have defined elsewhere.



Volume Monitors • In ‘Monitors’, press ‘Create...’ for a Volume Monitor

– Enter ‘component-temp-mon’ for the name

– Check the box to Plot and set the window number to 3

– Choose Volume Average for the report type

– Choose Static Temperature for the variable

– Select ‘solid_heatsource’ as the cell zone

– Click OK and then OK again


Solver controls Solution Methods > Pressure-Velocity Coupling • Select Coupled Scheme • Switch on Pseudo Transient Solution Methods > Spatial Discretization > Pressure • Change the pressure scheme to Body Force Weighted • Leave Momentum and Energy at 2nd Order Upwind Solution Initialization • Switch to Standard Initialization, Compute from inlet • Click the Initialize button

Run Calculation > Pseudo Transient Options • Select Time Step Method User Specified • Use Pseudo Time Step 10s for Fluid and 1000 s for Solid The solution is now ready to run. However this will take 5-10 minutes to converge, so you may prefer to fast-track to pre-converged data file we have supplied:

– To run the model yourself, enter 150 Iterations then Calculate – To use the supplied data file (ws6_no-radiation.dat.gz): • Running Fluent standalone use File > Read Data • Running Fluent in Workbench use File > Import Data (Fluent File menu)



Comments on Solver controls

The solver settings are tuned for an overall robust solution of most situations. In this model we require the Body Force Weighted pressure scheme to account for the natural convection effects. Solution initialization is used to provide the first guess prior to the first solver iteration, and it should be as close to the final solution as practical. Models with natural convection often show transient behaviour in some parts of the flow. Using Pseudo-Transient with large time steps can sometimes (as in this case) enforce a steady state solution.



Quick Post-processing Check overall heat and mass balances • Reports > Fluxes > Set Up

• Select the Inlet and Outlet surfaces, then click Compute

– The net imbalance mass flux is shown under Net Results

– Note that the net imbalance is very small relative to the boundary mass flow

• Switch to Total Heat Transfer Rate. Select all walls, the inlet, and the outlet and click Compute

– Note that the difference equals the energy source input to the package (75W)



Quick Flow Visualization

Create an iso-surface at x=0 (Surface -> Iso-Surface)

• Create an iso-surface at x=0 (Surface -> Iso-Surface)

• Display velocity vectors on the iso-surface

– The vectors show the formation and development of a wall plume above the component



Save Case and Data Files for Later Use

A later part of this Workshop will show you a comparison of results both with and without Thermal Radiation

To retain this set of results use the top menu to:

– If using Fluent standalone

• File >Write > Case & Data…

– If using Fluent under Workbench

• File >Export > Case & Data…

• Change to the working directory and label the file logically

TIP

• Adding the .gz extension will compress the case and data files, reducing hard disk usage

• Fluent can read in these compressed files, you do not need to manually uncompress them later



Radiation Model Setup

The temperature difference across the air space is notable, and therefore heat transfer via thermal radiation may be significant

Go to the Models tree item and select Radiation. • Enable the Surface-to-Surface (S2S) model • Click OK, then reopen the Radiation Model panel • Click the Settings Button to define Model Parameters

– Manual Options – 1 Face Per Cluster and Apply to All Walls – Select Face to Face as the Basis and the Ray Tracing

Method – OK

• Either: – (this will take a few minutes) click on the

Compute/Write/Read button and enter a filename – or click on Read Existing File and Load

ws6_viewfactor.s2s.gz (recommended) • Click OK when the S2S view factor step is complete



The model uses a ray tracing method, and this calculation is completed prior to the main solution. Thus, whilst the set up time is slightly longer due to the calculation of the view factors, the overall solution time is lower when compared to alternative radiation models available within ANSYS Fluent.

The method determines the view factor from each wall (or boundary) surface facet (mesh cell) to every other facet. Clustering is used to reduce the number of facet calculations needed in the actual solution. Neighbouring facets are grouped together based on the set values and other geometric factors.

The documentation contains full details of the model.

Comments on S2S Radiation model



Revise Boundary Conditions

The surfaces surrounding the fluid region now require an emissivity value for the radiation model

• Open the wall_left boundary condition

– under the thermal tab change the Internal Emissivity to 0.9

• Click the Copy button and copy the boundary conditions to wall_right and wall_top



Revise Boundary Conditions

Set the emissivity for following zones

Zone Emissivity

inlet 1

outlet 1

wall_heat_sink-shadow 0.9

wall_board-shadow 0.9

wall_heat_source 0.3

Note this panel is slightly different to those in the previous slide as these are coupled walls

– that is they do not make up the outer boundary of the domain. The internal

emissivity setting must be applied to walls where "fluid" is the adjacent cell zone.



Solving with Radiation Solve the flow field again (this time with radiation enabled) • (If you have time) solve for 200 more iterations, save the case and data files and exit

Fluent • If you are running Fluent in Workbench, select “Use settings changes for current and future

calculations” when prompted after clicking Calculate

• If you are short of time you may want to stop the solution prematurely and proceed to the post-processing. We have supplied a converged results file incorporating thermal radiation (ws6_s2s-radiation.cas.gz)



Post-processing can be done either in Fluent or CFD-Post • Both methods have their advantages • In this tutorial we are going to take advantage of CFD-Post’s ability to compare two

models simultaneously • The case comparison tool allows two different setups to be shown side by side and

any differences between the two cases identified • We will compare the latest results (with radiation) with those saved earlier (no

radiation)

Fluent in Workbench • Choose a Results component from the Component Systems in Workbench • Connect the Fluent solution panel to Results • Open the Results; this opens CFD-Post with the result of the radiation calculation

labelled as ‘FLU’ – If the instructions were not followed step by step, it might have a different name,

but that would not be a problem

Fluent Standalone • Start CFD-Post from the menu system/icon

Post-processing using CFD-Post



Case Comparison – Within Workbench

If running CFD-Post standalone, go straight to the next slide

If running within workbench: File > Load Results • Select the non-radiation case saved earlier. (the supplied file is ws6_no-radiation.dat.gz )

• ‘Keep current cases loaded’ should be already ticked • Select ‘Open’

From the toolbar, select the Case Comparison Icon: In the Case Comparison details (lower left corner of GUI) • Check the box “Case Comparison Active” • Change the order of the results, so

– Case 1 is the no-radiation case, – Case 2 the results with radiation ‘FLU’

• Apply

• Skip the next slide (for standalone CFD-Post)



Case Comparison – Outside Workbench For those using CFD-Post outside of Workbench File > Load Results

• First select the non-radiation .dat file saved earlier (the supplied file is ws6_no-radiation.dat.gz) Click ‘Open’

File > Load Results

• Tick the box to “Keep current cases loaded” • Load the results file from containing radiation (the supplied file is ws6_s2s-radiation.cas.gz) • Click ‘Open’

From the toolbar, select the Case Comparison Icon: In the Case Comparison details (lower left corner of GUI) • Check the box “Case Comparison Active” • Apply



Displaying Temperature Temperature will be a key variable for any electronics cooling application so it will be displayed in several locations

i. in the flow

ii. on the surfaces of the solid region

iii. by extracting the maximum temperature within the component

i) FLOW:

Create a YZ plane

• Insert > Location > Plane

– Call it Centre

– Located at X=0

– Colour it using the variable Temperature.



Displaying Temperature ii) SOLID:

Create a contour plot

• Insert > Contour

– Use the fluid-solid interfaces as the location

• wall_board shadow, wall_heat_sink shadow and wall_heat_source

• Multiple locations can be selected by clicking and holding CTRL (select surfaces from both sets)

– Set the variable to Temperature using the Global Range

– Apply

• In the Outline tree, deselect the plane called “Centre” and the contour plot associated with it



Reporting Temperature iii) Computing Maximum Temperature

In the top toolbar, click on the icon to launch the function calculator

• Set the options

– maxVal

– solid_heatsource

– All Cases

– Temperature

• Then press ‘Calculate’

Note that with radiation, the temperature in the solid is lower than when radiation was not included.

The cooling of the component is mirrored with an increase in the temperature of the walls around the fluid zone. This can be seen if you plot the temperature on the walls or use the Function Calculator with the areaAve function.



To visualize flow patterns different methods can be used including Streamlines, Vector Plots and Isosurfaces

Insert an Isosurface

• Insert > Location > Isosurface

• set the Variable to Velocity with a value of 0.5m/s.

• Gradually reduce the value to 0.2 and notice that for the radiation case higher speed flow can be observed close to the fluid walls as well as the PCB

Insert a Vector Plot

• Insert > Vector

• Set Location to Centre

• Change Sampling to Equally Spaced with 1000 Points

• Go to the Color Tab and set Range to Local

• Go to Symbol Tab and Select “Normalize Symbols” – All of the vectors will be the same length, making it easier to investigate regions of the model where the velocity magnitude is small

Flow Displays



Further work

If you would like to experiment further with this example, you could investigate the consequences of changing:

Numeric Schemes • Run First Order Upwind instead of Second Order Upwind Discretization

Modeling • You could modify the Radiation Model Parameters

– Resolution @ View Factors and Clustering Panel

Boundary Conditions • Modify the Energy Source Term

• Modify the Material Properties



Wrap-up

This workshop has shown the steps needed to set up a simulation that includes:

• Heat conduction within a solid

(indeed several solids, each of different material properties)

• Conjugate heat transfer to the fluid from the solid

• The effects of natural convection

• The effects of thermal radiation

In addition, a side-by-side comparison of the results has been performed in CFD-Post.

In this case we were interested in the maximum temperature in the electronic

component. We have seen that radiation has a strong influence on the results.

Knowing your aims from the start will help you make sensible decisions of how much of

the part to simulate, the level of mesh refinement needed, and which numerical

schemes should be selected.



If you are in a training facility with an EKM database and Web User Interface, you may be interested in working through the remainder of the slides

This capability may not be available in all ANSYS training facilities

Check with your instructor regarding whether this is possible in your training facility

Optional: Archiving in EKM


Archiving in EKM

Documentation and archiving is often neglected in simulation projects

Please upload both case files for exploring some features of EKM

1. Start EKM WEB UI

Introduction Basic Model Setup Radiation Model Setup Solving PostProcessing Archiving Summary

or it might already be bookmarked under Favorites

Important: If you are not located in Darmstadt, your trainer will provide the correct URL for your location


Archiving in EKM

2. Log into EKM WEB UI


Benutzername: trainingX Password: trainingX123 Arbeitsbereich: train-workspace Please see next slide for login details

Important: If you are not located in Darmstadt, your trainer will provide the correct user name, password and workspace name.


Darmstadt Trainingsroom

training1 training2 training3 training4

training5 training6 training7 training8

trainer door


Important: If you are not located in Darmstadt, your trainer will provide the information required at your location.


Archiving in EKM


3. Click on Repository

4. Navigate to TEMP-train-ekm-test


Archiving in EKM


5. Click „Next“

6. Click „Add“ 7. Select case files

5. Upload

6. Click „Add“

7. Select case file and click „Open“


Archiving in EKM


8. Click „Add“ again 9. Select 2nd case file and click „Open“

10. Click „Next“


Archiving in EKM


11. Click „OK“ 12. Click on a case file

13. Inspect Simulation Details report


Archiving in EKM


14. Select 2 files, RMB Comparison Report 15. Click „Next“ 16. Click „Next“


Archiving in EKM


19. Inspect Comparison Report 17. Click „Next“ 18. Click „OK“


Archiving in EKM


20. Close EKM by „Logout“


Overview: Challenges in simulation

Multiple analysts working on same project

Search and reuse previous simulations

Global deployment and what-if studies

?

Collaboration Search and Reuse

Deployment

Documents

Fluent-Intro 15.0 WS06 Electronics Cooling Plus EKM Rev2