Topology optimization and bionic analysis of heat sink fin configuration based on additive manufacturing technology

Fins are extensively employed in heat sinks for high heat flux components. In this study, three distinct objective functions, namely temperature gradient minimization (TO-I type fin), average temperature minimization (TO-II type fin), and entransy dissipation minimization (TO-III type fin), are established for topology optimization design of the heat sink fin structure to effectively minimize the temperature of the heat source. By conducting a comparative analysis of the configuration features and thermal performance of optimized fins with different objective functions, it is evident that the TO-I type fin exhibits superior thermal performance. When the fin volume fraction phi is 0.3, the heat source center temperature of TO-I type fin is 2.67 K and 4.55 K lower than that of TO-II type fin and TO-III type fin, respectively. Meanwhile, the bionic analysis of the optimized fins under different objective functions using fractal theory reveals that the fractal dimension of the TO-I type fin is 1.4038, which is the closest to the average fractal dimension of many kinds of leaf veins in nature (Df = 1.3762), which indicates that the optimized fins have the bionic characteristics most similar to those of the leaf blade. Finally, the three topology optimization fins were fabricated using boundary-filtering optimization 3D printing technology. Comparative tests verified the advantage of minimizing the temperature gradient as the objective function of topology optimization and demonstrated its potential for thermal performance and lightweighting applications, especially under high heat source operating conditions.