Morsi, Ashraf, Razzaq, Mohammed Abdel, Khalid, Youssef, Naser, Mohamed, Elkholy, Mohamed, Elhagali, Ibrahim and Maklad, Osama ORCID: https://orcid.org/0000-0001-6893-2654 (2026) Thermo-hydraulic performance of microchannel heat sinks with square pin-fin geometries: a numerical investigation. In: The 32nd THERMINIC International Workshop on Thermal Investigations of ICs and Systems, 16th - 18th September 2026, Berlin.

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Abstract

The continued rise in power density of modern electronic devices demands compact cooling solutions capable of dissipating extreme heat fluxes. This paper presents a three dimensional computational fluid dynamics (CFD) investigation of the thermo-hydraulic performance of a multi-inlet microchannel heat sink (MCHS) incorporating square pin-fin arrays, with a 25% propylene glycol-water mixture (PG25) as the working fluid. A five-inlet manifold configuration is adopted to improve flow uniformity, and seven optimisation phases are systematically evaluated: five-inlet, five-inlet with square pins, chamfered pins (10%, 20%, 30%), cut square pins, filleted square pins, aspect-ratio-modified pins with cut-through holes, a novel high-performance design, and a fin-removal strategy. The base case (five-inlet with square pins) achieves a heat transfer coefficient (HTC) of 26,452 W/m²K at a pressure drop of 128.5 Pa and a pumping power of 0.001646 mW/mm². Among the configurations studied, the novel design (Novel 1) achieves the highest HTC of 41,975 W/m²K, representing a 40.2% improvement over the base case, albeit at a significantly elevated pumping power. Chamfered pins provide progressive hydraulic relief with a modest thermal trade-off, while the aspect-ratio modification with cut-through holes delivers a 5.1% HTC improvement with moderate hydraulic cost. The results demonstrate that geometric optimization can yield substantial performance improvements and provide guidelines for the design of high-performance microchannel cold plates.

Item Type:	Conference or Conference Paper (Paper)
Uncontrolled Keywords:	micro-channel heat sink, thermal management, pin fins, computational fluid dynamics (CFD), electronic cooling, pressure drop, conjugate heat transfer, Nusselt number
Subjects:	Q Science > Q Science (General) T Technology > T Technology (General)
Faculty / School / Research Centre / Research Group:	Faculty of Engineering & Science Faculty of Engineering & Science > School of Engineering (ENG)
Last Modified:	16 Sep 2026 08:46
URI:	https://gala.gre.ac.uk/id/eprint/54301

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