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An isogeometric analysis-based topology optimization framework for 2D cross-flow heat exchangers with manufacturability constraints

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Abstract

Heat exchangers (HXs) have gained increasing attention due to the intensive demand of performance improving and energy saving for various equipment and machines. As a natural application, topology optimization has been involved in the structural design of HXs aiming at improving heat exchange performance (HXP) and meanwhile controlling pressure drop (PD). In this paper, a novel multiphysics-based topology optimization framework is developed to maximize the HXP for 2D cross-flow HXs, and concurrently limit the PD between the fluid inlet and outlet. In particular, an isogeometric analysis solver is developed to solve the coupled steady-state Navier–Stokes and heat convection–diffusion equations. Non-body-fitted control mesh is adopted instead of dynamically remeshing the design domain during the evolution of the boundary interface. The method of moving morphable voids is employed to represent and track boundary interface between the hot and the remaining regions. In addition, various constraints are incorporated to guarantee manufacturability of the optimized structures with respect to practical considerations in additive manufacturing, such as removing sharp corners, controlling channel perimeters, and minimizing overhangs. To implement the iterative optimization process, the method of moving asymptotes is employed. Numerical examples show that the HXP of the optimized structure is greatly improved compared with its corresponding initial design, and the PD between the fluid inlet and outlet is controlled concurrently. Moreover, a smooth boundary interface between the channel and the cold fluid, and improved manufacturability are simultaneously obtained for the optimized structures.

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Acknowledgements

The research in this paper was sponsored by the Army Research Laboratory and was accomplished under Cooperative Agreement Number W911NF-20-2-0175. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Army Research Laboratory or the U.S. Government. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation herein. This work used the Extreme Science and Engineering Discovery Environment (XSEDE), which is supported by National Science Foundation grant number ACI-1548562. Specifically, it used the Bridges-2 system, which is supported by NSF award number ACI-1928147, at the Pittsburgh Supercomputing Center (PSC).

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  1. Department of Mechanical Engineering, Carnegie Mellon University, 5000 Forbes Avenue, Pittsburgh, PA, 15213, USA

    Xuan Liang, Angran Li & Yongjie Jessica Zhang

  2. Department of Materials Science and Engineering, Carnegie Mellon University, 5000 Forbes Avenue, Pittsburgh, PA, 15213, USA

    Anthony D. Rollett

  3. The NextManufacturing Center, Carnegie Mellon University, 5000 Forbes Avenue, Pittsburgh, PA, 15213, USA

    Xuan Liang, Anthony D. Rollett & Yongjie Jessica Zhang

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  1. Xuan Liang
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Liang, X., Li, A., Rollett, A.D. et al. An isogeometric analysis-based topology optimization framework for 2D cross-flow heat exchangers with manufacturability constraints. Engineering with Computers 38, 4829–4852 (2022). https://doi.org/10.1007/s00366-022-01716-4

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