DESIGN AND MANUFACTURING TECHNIQUES INVOLVED IN

HEAT TRANSFER FINS

Submitted By:
Nishita Gogoi
M. Tech. 1stSemester (Design & Manufacturing)
Scholar ID: 2426204

DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY SILCHAR

SILCHAR-788010, ASSAM
2024
 CONTENTS

• Introduction

• Literature Survey

• Design considerations

• Manufacturing Techniques

• Discussion and Future Direction

• Conclusion

• Reference

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 INTRODUCTION
 Introduction to Heat Transfer Fins
Fins are the extended surface used when there is a need to increase the heat transfer rate. The process of heat transfer through fins is
primarily driven by the principles of conduction, convection, and radiation.
 Types of Fins:
• Straight fins
• Radial fins
• Annular fin
• Pin fin
Fig 1: a) Straight fin b) Annular fin c) Pin fin d)Radial fin
 Application
• Radiators in automobiles for engine cooling.
• Heat sinks in electronic devices to dissipate heat.
• Air conditioning units for efficient cooling.
• Heat exchangers for improved thermal performance.
• Industrial processes like drying and heating. Fig 2: a) Radiator b) Heat sinks

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 Literature Survey
S. Authors Title of the Inferences Drawn
N. Research
1 R. Kocurek, Manufacturing This paper studied that Welded finned tubes in power equipment improve energy efficiency and reduce operational
J. Adamiec technologies of costs by lowering flue gas temperatures. Several production technologies exist, including plastic working, high-
finned tubes frequency, arc, and MAG welding.
1.Cross-finned tubes, produced via cold rolling (depressing for low fins, grading for high fins), enhance thermal and
chemical resistance in heat exchangers for temperatures up to 200°C.
2013 2.Hot rolling forms finned tubes by winding and clamping tape into a notched groove, allowing steel pipes to
function up to 450°C with aluminum fins and 500°C with stainless steel fins.

Fig: 3. The manufacturing process of finned

tubes: a) a set of three rolls of rolled tube, b)
high finned tubes manufactured by depressing
and grading
3.Efficiency of cross-finned tubes is improved using MAG and laser beam welding, with automatic MAG welding
commonly used in industrial production.
4.Welding contact currents frequency (HF) in resistance welding uses high-frequency heating for melting surfaces,
with typical issues like local burnout, surface flooding, and weld splatter.

Fig:4. The welding process currents of high

frequency (HF) of finned tubes (a) , the pipe is
made with the rib serrated HF technology. (b)

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 Literature Survey
S.N. Authors Title of the Research Inferences Drawn

2 L.Prabhu, Design and analysis of This paper studied that Fins with rectangular configurations provide superior heat
M.Ganesh different types of fin transfer compared to other types due to their larger surface area and more uniform
Kumar, configurations using temperature distribution. The minimum temperature at the fin's tip enhances thermal
PrasanthM, Ansys. efficiency, making rectangular fins more effective. Optimizing the size of rectangular fins
Parthasarathy M. reduces costs while maximizing heat transfer performance.
2018

FIN MAXIMUM MINIMUM

CONFIGURATI TEMPRATURE TEMPRATURE
ON
CIRCULAR 200 166.34

SQUARE 200 162.46

RECTANGULAR 200 155.62

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 Literature Survey
S.N. Authors Title of the Research Inferences Drawn

3 Priscilla Jia Yuan Thermal performance of This paper explores the use of Bézier curves for designing novel pin-fin shapes. Their flexibility makes
Fok, Pengfei Liu, cold plates with novel them ideal for shape optimization, allowing for a wide range of forms within the design space. Bézier
Ranjith pin-fins designed using curves offer significant potential for improving pin-fin performance
Kandasamy,Teck Bézier curves
Neng Wong
2024
4 A. Broatch, Rapid aerodynamic This paper highlights that Scaled wind tunnels are used to characterize turbofan heat exchangers, but
J. García-Tíscar, characterization of intrusive measurements can affect aerodynamics. A non-intrusive methodology is proposed to assess
P. Quintero, surface heat exchangers surface heat exchangers. 3D-printed heat exchanger fins successfully replicate pressure losses.
A. Felgueroso for turbofan aeroengines
through optical
techniques and additive
manufacturing

2024

Fig: 6. Pressure drop induced by the fins of each

model Fig: 7. Comparison of the vibration spectrum of the aluminum and 3D printed models.
 Literature Survey
S.N. Authors Title of the Research Inferences Drawn

5 Hussain Sallar, Hydro-thermal performance

This study introduces a heat sink with an innovative I-shaped pin fin design that reduces flow
Muhammad of an I-shaped pin fin
Irfan, microchannel heat sink with resistance and enhances heat transfer efficiency. A 3D numerical analysis using ANSYS Fluent
Muhammad variable pin fin height,
investigates its hydrothermal performance, optimizing fin height and thickness for the best results.
Mahabat Kha, thickness and orientation
Muhammad
Wakil Shahzad. 2024

Fig: 8. Geometry of the heat sink highlighting the dimensional details (a) xy-cross-section (b) Isometric view
(c) Top view (d) Cross section of a single I-shaped pin fin.

6 Ahmed Waheed Evolutionary design of

This paper presents an evolutionary design of triangular fins in forced convection, starting with larger
Mustafa, Salemaa triangular multiscale fins in
Rashid Salih. cross-flow fins, followed by smaller fins placed between them, and finally the insertion of the smallest fins.

2024

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 Literature Survey

S.N. Authors Title of the Research Inferences Drawn

7 Yu Zhao, Xinzhu Mou,

Topology optimization and bionic This study optimizes heat sink fin designs using topology optimization with three
Zhenqian Chen,
Menglong Hao, Li analysis of heat sink fin configuration objective functions. The performance of the optimized fins was analyzed under
Chen, Bo Xu.
based on additive manufacturing varying volume fraction, heat source power, and material thermal conductivity,
technology. with insights drawn from bionic fractal theory. Heat dissipation experiments were
conducted using boundary filtering to assess the results.
2024

Fig: 9. (a)Schematic diagram of the heat sink; (b) design field of the topology optimization.

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 DESIGN CONSIDERATIONS
 FIN GEOMETRY
 Rectangular Fins: These are widely used due to their simplicity and large surface area.
 Pin Fins: These cylindrical fins enhance heat dissipation by promoting better airflow and minimizing air resistance
 Triangular Fins: Triangular cross-sectional profiles can be advantageous in applications where weight needs to be minimized.
 Fin Height and Thickness
 Fin Height:
• Tall Fins: Increase the surface area and provide greater heat dissipation capacity but also add to the weight and cost. They can be
effective when airflow is plentiful.
• Short Fins: Shorter fins are also beneficial in systems where minimizing material usage is a priority.
 Fin Thickness:
• Thick Fins: Provide a better path for heat conduction from the base to the tip but reduce the available surface area for convection.
Thicker fins are suitable for highly conductive materials like copper.
• Thin Fins: Maximize the surface area for heat exchange but may have higher thermal resistance, especially at the fin tip. Thin fins are
typically used in lightweight applications like consumer electronics.
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 DESIGN CONSIDERATIONS
a)
b)
 Material Selection

• Aluminum Fins: Provide the best overall value.

c)
Fig:10. a) Aluminum Fins
• Stainless Steel Fins: Fight high external corrosion. b)Stainless steel fin
c) Copper fins

• Copper Fins: Provide the best heat transfer.

 Temperature Distribution

• Longer Fins: They offer more surface area, longer fins can suffer from reduced temperature differentials along their length,

leading to inefficient heat dissipation near the tip.

• Shorter Fins: May offer better overall efficiency since the temperature gradient is maintained across a smaller distance.

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 MANUFACTURING TECHNIQUES

 Welding-Based Manufacturing Techniques

 High-Frequency Welding: This technique is widely used in the production of finned tubes, where fins are welded to the tube by

applying high-frequency electrical current. It provides strong bonds but may introduce imperfections like incomplete fusion or spatter,

as noted in the paper by R. Kocurek, J. Adamiec.

 Metal Active Gas (MAG) Welding: MAG welding, also described in the same paper, uses an active shielding gas to weld the finned

tubes. This method improves joint strength but may cause surface roughness, which could slightly affect the thermal efficiency.

 Application: These welding methods are primarily used in large-scale heat exchangers where durability and the ability to handle high-

pressure steam or gases are important.

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 MANUFACTURING TECHNIQUES
 Additive Manufacturing (3D Printing)

Additive manufacturing is revolutionizing fin production, allowing for complex and optimized designs that traditional manufacturing methods

cannot achieve. The L.Y.X. Lum, K.C. Leong, J.Y. Ho and Nam Phuong Nguyen et al. papers highlight the advantages of additive manufacturing

for fins.

 Laser Powder Bed Fusion (LPBF): This method uses a laser to selectively melt and fuse powdered metal layer by layer, creating complex fin

geometries that can optimize heat transfer.

 Selective Laser Melting (SLM): SLM, a subset of additive manufacturing, is useful for producing 3D-printed pin-fin arrays with precise

control over flow patterns and temperature distributions. These fins can be designed with fractal geometries, as discussed by L.Y.X. Lum et al.,

to improve boiling efficiency.

 Application: Additive manufacturing is ideal for applications where customized, optimized fin designs are needed, such as in electronics

cooling or advanced heat sinks.

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 MANUFACTURING TECHNIQUES
 Stamping and Machining
 Stamping: This process involves cutting and shaping thin sheets of metal into fin shapes using a press. It’s a high-speed, cost-effective
method for producing large quantities of fins with consistent quality.
 CNC Machining: Computer Numerical Control (CNC) machining allows for precise cutting and shaping of fins from solid blocks of
material. This technique offers greater accuracy and is suitable for producing fins with specific geometries (e.g., I-shaped or triangular fins),
as discussed in the Hussain Sallar et al. paper.
 Application: Stamping is commonly used in automotive radiators, while CNC machining is favored for specialized or low-volume heat
exchangers where precision is more important than speed.
 Hydroforming
 Hydroforming of Pin Fins: As described in the Hussain Sallar et al. study, hydroforming can create variable-height and -thickness pin fins,
optimizing fluid dynamics and reducing flow resistance.
 Application: Hydroforming is typically used for compact heat exchangers in aerospace and automotive industries where lightweight and
robust structures are needed.

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 MANUFACTURING TECHNIQUES
 Extrusion

 Continuous Extrusion: This process pushes aluminum or copper billets through a die to create long sections of finned tubes. The fins can

be later cut to size. It is one of the most efficient ways to mass-produce fins with uniform thickness and spacing.

 Application: Extrusion is widely used for HVAC systems, air-cooled heat exchangers, and radiators where long, continuous fin arrays are

needed.

 Topology Optimization

 Bionic and Fractal Designs: As mentioned in the Yu Zhao et al. paper, topology optimization combined with bionic analysis allows the

creation of highly efficient fin designs that mimic natural structures.

 Application: Topology optimization is used for high-performance applications, such as advanced heat sinks in electronics, where efficiency

and space are critical factors.

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 DISCUSSION AND FUTURE DIRECTION
 Discussion
 Rectangular Fin Efficiency: Rectangular fins offer superior heat transfer due to larger surface areas and uniform temperature distribution,
reducing manufacturing costs while maintaining performance (Prabhu et al.).
 Additive Manufacturing of Fins: Additive manufacturing enables complex fin designs, such as fractal and 3D-printed pin fins, improving
heat transfer by enhancing fluid dynamics and managing bubble behavior (Nguyen et al., Lum et al.).
 Innovative and Optimized Fin Designs: Novel configurations like Bézier curve-designed pin fins and I-shaped pin fins reduce flow
resistance and enhance heat transfer, while multiscale triangular fins improve thermal efficiency in forced convection (Fok et al., Sallar et
al
 Future Directions
 Advanced Additive Manufacturing: Future research should focus on multi-material 3D printing to create fins with customized thermal
properties, enhancing heat transfer in critical applications like electronics cooling and aerospace.
 Bionic and AI-Driven Designs: Exploring nature-inspired and AI-simulated fin designs could lead to more efficient heat transfer
configurations, optimized for various industrial applications.
 Hybrid Manufacturing and Computational Tools: Combining traditional and additive manufacturing techniques with advanced computational

models can streamline fin production, improving performance while reducing costs in industries like automotive .
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 CONCLUSION

 Welded and additively manufactured fins enhance heat transfer efficiency, though imperfections like incomplete fusion must be

addressed.

 Innovative designs, such as pin fins with Bézier curves and multiscale fins, reduce flow resistance and improve heat dissipation.

 Topology optimization using bionic and fractal principles maximizes thermal performance while minimizing material use in cost-

effective heat exchangers.

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THANK YOU

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