Workshop 06

Electronics Cooling with

Natural Convection and Radiation
15.0 Release

Introduction to ANSYS
Fluent
2014 ANSYS, Inc.

February 28, 2014

Release 15.0

Introduction
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)

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Before Starting
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.

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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

Drag

Mesh File
Select the mesh file heatsink.msh
Click Open

Launch Fluent using the

default options
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Mesh Import (Stand-alone)

If working with Fluent Standalone
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

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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

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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

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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.

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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
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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

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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 (its still in the database).
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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.

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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

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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

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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

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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 45C, then OK

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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.

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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

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Comments on Cell and Zone Conditions

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)
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Comments on Cell and Zone Conditions

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!

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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

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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.

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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

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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)
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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.

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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)

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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

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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
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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
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Comments on S2S Radiation model

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.

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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

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Revise Boundary Conditions

Set the emissivity for following zones
Zone

Emissivity

inlet

outlet

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.
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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)

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Post-processing using CFD-Post

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-Posts 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
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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)

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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

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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.

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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

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Reporting Temperature
iii) Computing Maximum Temperature
In the top toolbar, click on the
calculator
Set the options
maxVal
solid_heatsource
All Cases
Temperature
Then press Calculate

icon to launch the function

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.
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Flow Displays
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
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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

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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.

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Optional: Archiving in EKM

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

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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

Important: If you are not located in

Darmstadt, your trainer will provide the
correct URL for your location
or it might already be
bookmarked under
Favorites

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Archiving in EKM
2. Log into EKM WEB UI

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

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Password: trainingX123

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Arbeitsbereich: train-workspace
Please see next slide for login details
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Darmstadt Trainingsroom
door

trainer

training1

training2

training3

training4

training5

training6

training7

training8

Important: If you are not located in

Darmstadt, your trainer will provide the
information required at your location.
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Archiving in EKM

3. Click on Repository

4. Navigate to TEMP-trainekm-test

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Archiving in EKM
5. Upload
6. Click Add

7. Select case file

and click Open

5. Click Next
6. Click Add
7. Select case files
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Archiving in EKM

8. Click Add again

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9. Select 2nd case

file and click
Open
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10. Click Next

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Archiving in EKM

11. Click OK

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13. Inspect Simulation

Details report

12. Click on a
case file

Basic Model Setup

Radiation Model Setup

February 28, 2014

Solving
49

PostProcessing

Archiving

Summary
Release 15.0

Archiving in EKM

14. Select 2 files,

RMB Comparison
Report
Introduction
2014 ANSYS, Inc.

15. Click Next

Basic Model Setup

Radiation Model Setup

February 28, 2014

Solving
50

16. Click Next

PostProcessing

Archiving

Summary
Release 15.0

Archiving in EKM

17. Click Next

Introduction
2014 ANSYS, Inc.

19. Inspect Comparison

Report

18. Click OK

Basic Model Setup

Radiation Model Setup

February 28, 2014

Solving
51

PostProcessing

Archiving

Summary
Release 15.0

Archiving in EKM
20. Close EKM by Logout

Introduction
2014 ANSYS, Inc.

Basic Model Setup

Radiation Model Setup

February 28, 2014

Solving
52

PostProcessing

Archiving

Summary
Release 15.0

Overview: Challenges in simulation

?
Collaboration

Search and Reuse

Deployment
Multiple analysts working on same project
Search and reuse previous simulations
Global deployment and what-if studies

2014 ANSYS, Inc.

February 28, 2014

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Release 15.0