Third Review Project Report

Submitted by

1. CHANDRAGIRI SUDARSHAN YADAV 1661417

2. AMBALA GOWTHAM REDDY 1660458
3. K PRUDVI RAJ 1661503
4. DASARI SAI CHARAN TEJ 1660604
5. KASARU VENKATESH 1661230

In partial fulfillment of the requirements for the award of the degree of

Bachelor of Technology
In
Mechanical Engineering

Under the Guidance of

Prof. Avinash Babu & Dr. Dileep V Nair

Department of Mechanical and Automobile Engineering
Faculty of Engineering

DEPARTMENT OF MECHANICAL AND AUTOMOBILE

ENGINEERING
FACULTY OF ENGINEERING, CHRIST (Deemed to be University)
Kumbalagodu, Kengeri, Bengaluru – 560074
NOVEMBER 2019-2020

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 TITLE OF THE PROJECT

EXPERIMENTAL STUDY ON STRAIGHT FINS ATTACHED

TO A CYLINDER

CHAPTER CONTENTS PAGE.NO

1. INTRODUCTION 4-9

2. LITERATURE REVIEW 10-11

3. ACTUAL WORK 12-23

4. REFERENCES 24

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ABSTRACT

Finned heat sinks are presently used for passive heat dissipation from LED luminaires and
similar electrical and electronic devices. An increase in the junction temperature drastically
reduces the reliability and efficiency of LEDs. The present study investigates the natural
convection heat transfer from heat sinks used in LED luminaires. A heat sink which consists
of straight fins attached to the cylindrical base is fabricated. The cylindrical base is vertically
oriented. A survey on existing research literature shows just one study on natural convection
from straight fins on the cylindrical base in vertical orientation, and the study indicated the
presence of an optimum number of fins for maximum heat transfer rate. When number of fins
are increased beyond the optimum, the heat transfer rate decreases due to the merging of
thermal boundary layers of adjacent fins. An existing numerical analysis proposed that the
heat transfer would be maximum when the number of fins = 30 on the heat sink with cylinder
diameter = 60mm, fin height = 70mm, fin thickness = 3mm. The main purpose of the present
study is to experimentally validate the numerical results and identify the existence of an optimal
number of fins for maximum heat transfer rate. The experimentally determined heat transfer
rates are compared for heat sinks with the number of fins at the optimum, below the optimum
and above the optimum. The heat sink material is Aluminum 6061. A universal frame is
designed to hold the heat sink in different orientations. Voltmeter, Ammeter are used to
measure the voltage and current across the circuit. Dimmerstat is used to regulate the wattage.
Temperature at the base of the cylinder and the lower surface of thermocol are used to calculate
the dissipated heat.

Keywords: LEDs, Heatsinks, Optimum.

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 CHAPTER-1

INTRODUCTION

Due to the increase in temperature in the LEDs, Electronic motor, etc., there will be a decrease
in performance and reliability of device. Heat sinks such as fins are used to remove the
unwanted heat. Fins play a major role in heat dissipation in LED’s, Electric motor. Heat transfer
is effected by the parameters like fin length(L), fin spacing(s), fin height(H), no of fins(N),
ambient temperature(Ta), base temperature(Tb), fin thickness(t) etc.,

Figure 1.1
From Figure 1.1,
H = Height of the fin
L = Length of the fin
t = Thickness of fin
S = Fin spacing

Fins are divided into different types based arrangement and shape of fins are
1. Pin- fin:

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 Figure: 1.2
2. Rectangular or flat plate fins

Figure: 1.3

3. Angular fins
4. Tapered fins.

As the number of fins increases the heat transfer rate is also increases this increase the
performance.

Advantages of fins:

 Heat transfer rate can be increased without any additional maintenance

 The cheapest way to increase the heat transfer rate

Disadvantages of fins:

 Bend of fins due to larger lengths

 Weight of the body increases which results in a decrease in overall efficiency

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Problem Formulation:
Nowadays the major problem associated with LED’s is the lack of proper cooling methods.
The heat loss inturn results in low efficiency, so utilization of fins provides a proper cooling
compared to other cooling methods and therefore implemented.

Problem Identification:
The LED's often facing problem-related to efficiency. Recent research proved that these lights are 20%
efficient. Remaining 80% loss is due to various losses like heat dissipation and some other factors.
Amongst that heat loss is the major drawback in reducing the efficiency of it. The temperature at the
junction is pretty high and an effective cooling mechanism should be employed.
Amongst all the cooling techniques natural convective heat sinks are most reliable, simple and cost-
effective.

Figure 1.4: Percentage of LED Lighting Failure Modes

Figure 1.5: Failure of LED's with an increase in temperature

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Problem definition and objectives:

 LED’s have suffered thermal problems due to internal increases in power density. Higher
force densities lead to an increase in the junction temperature, which is harmful to device
performance and reliability.
 Among various cooling methods, natural convective heat sinks have proven to be the best for
LEDs, because of their inherent simplicity, reliability, and low long-term cost

Objectives:

1. To identify the existence of an optimal number of fins for maximum heat transfer rate using a
numerical study.
2. To study how the optima vary with parameters like cylinder height, cylinder diameter, and fin
height.
3. To conduct experiments to validate the numerical model.

Parameters:
Fin length (L)
Fin thickness (t)
Fin height (H),
Number of fins (N)
Ambient temperature (Ta)
Base temperature (Tb)

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Modes of Heat transfer:

There are three different modes of heat transfer

1. Conduction
2. Convection
3. Radiation

Conduction:
Conduction is the process in which the heat transfer occurs due to the contact, heat transfer
always flows from a hot body to a cold body without any molecular excitation. Conduction
undergoes in solids
Example: When a spoon is dipped in the hot water as soon as the tip is heated the heat flows
from and reaches the other end (handle), so because of the conduction process we can feel the
temperature at the end of the handle.

Q=K *A *(T2-T1)

Q= Heat Dissipation (w\m2)

A=Area of cross-section (m2)
K= Thermal conductivity (w\m* K)
T1= Ambient temperature (K)
T2= Base temperature (K)

Convection:
Convection is the process in which heat transfer occurs due to the flow of fluid over the
surface due to molecular excitation. Convection applies to liquids and gases.
Example: Heating of water in a pan

Q=h *A *(T2-T1)

Q= Heat Dissipation (w\m2)

A=Area of cross-section (m2)
h= Convective heat transfer coefficient (m2 /K)
T2= Ambient temperature (K)
T1= temperature (K)

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There are two types of convection:
1. Natural convection
2. Forced convection

Natural convection:
This is the process in which heat transfer occurs due to difference in temperatures without
any external force
Example: When we place the hot coffee in the open air, due to a difference in temperatures
of air and coffee, heat transfer occurs.

Forced convection:
This is the process in which heat transfer occurs due to a difference in temperatures by using
external force.

Example: Hot coffee placed nearer to the fan

Radiation:
Radiation is the process in which heat transfer occurs due to electromagnetic waves. It is
independent of the medium

Example: Sunrays touching the earth surface is a radiation process

Q= σ*e*A*T4

Q= Heat Dissipation (w\m2)

A=Area of cross section (m2)
e = Emissivity
σ = Stefan’s Boltzmann constant=5.67*e^-8 (w\m2*k*T4)

Emissivity:
Effectiveness of the surface of a material in emitting energy in thermal radiation. Emissivity
is a dimensionless quantity. The value always ranges from 0 to 1

LIMITATIONS:

1. It is difficult to obtain exact optima using experimental study

2. It is expensive to do a parametric study experimentally
3. Due to the cost factor, only 3 heat sinks have been tested
4. Parameters like fin height, fin thickness, fin width are maintained constant

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 CHAPTER-2

LITERATURE REVIEW

Review of literature

Geometric parameters like fin spacing, fin height, fin thickness, fin length and base to ambient
temperature will effect the rate of heat transfer. Graphically plotted results for range of values
for fin spacing (5.75-85.5mm), fin height (5-25mm), fin thickness(3mm), fin length (250-
340mm) against heat dissipation shows that rate of heat transfer increases with increase in
values of parameters from the research results done by Yazicioğlu, B. and Yüncü, H., [1].

The temperature distribution is a key factor in heat dissipation, temperature distribution

decreases with an increase in fin height and thereby increases the heat transfer to prove these
experiments are done with six aluminum fins with a fixed range of fin heights. Further
experiments are conducted and the maximum and minimum heat transfer rates with respect to
the fin heights are specified from the research done by Jubear, A.J. and Al-Hamadani, A.A., [2]

Different geometries of heat sinks like the shape of the heat sink, structure of fins, mass of heat
sinks, temperature distribution, and thermal resistance vary with metals. The material
properties of metals vary with the change in temperature and it greatly effects heat transfer
from the research done Bouknadel, A., Rah, I., El Omari, H., & El Omari, H..,[3]

The effects of various fin numbers, fin heights, and base temperature on natural convection
from horizontal cylinders with longitudinal plate fins were explained, as the number of fins
increases the heat transfer rate increases accordingly. At some point, the heat transfer rate starts
to decrease due to the merge of thermal boundary layers of adjacent fins which are termed as
an optimum point. Thus, we got to know that there exists an optimum point from the research
done by Kim, H.J., An, B.H., Park, J. and Kim, D.K.,[4]

A small change in the dimensions can lead to increase or decrease of the heat transfer rate, In
case of pin-fin arrangement, the draft angle of 1-degree expansion decreases the minimum
temperature nearly by 5K with respect to the zero degrees expansion, and decreases the
maximum temperature nearly by 5K compared to zero degrees expansion these results are
known by numerical analysis from the research done by Arefin, A. M. E., [5]

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As the fin length varies heat transfer rate also varies experimental method is used and results
where plotted and if we keep on increases the number of fins the fin spacing varies when the
fin spacing reaches the optimum we can call it as optimum spacing, it is the point or instance
where there will be maximum heat transfer will occur. Thus optimum-spacing will provide
maximum heat transfer from the research done by Jones, C. D., & Smith, L. F., [6]

Numerical analysis is carried out to study the natural convection heat transfer along with the
vertical cylinder heat sink with longitudinal fins, a numerical model is created based on the
CFD method. And it also discusses the thermal boundary layers and also about airflow patterns.
The analysis is carried out by creating a fluid domain from the research done by Shen, Q., [7]

As an application of LED’s, Experimental and numerical study of rectangular fins attached to

the rectangular block is done. This also explains that the variations in inclinations of rectangular
fins orientation vary the heat transfer rate. The inclinations more than 10 degrees will effect
the heat transfer. The blockage of convection flow and natural convection flow are two factors
that effect the heat dissipation from the research done by Shen, Q., Sun, D., Xu, Y., [8]

The computational study of steady-state thermal and airflow through a rectangular channel with
pin-fins mentioned that there will be maximum heat transfer when fins are placed in the
staggered model instead of placing them in the inline model and it also suggests that aluminum
fins will provide the maximum exit temperature compared to the steel and nickel fins from the
research done by Dewan, A., et al, [9]

Critical Review:

1. There is only one study on natural convection from straight fins on the
cylindrical base in vertical orientation, and the study indicated the presence of
an optimum number of fins for maximum heat transfer rate.
2. The present study investigates the optimum number of fins with experimental
study.
3. This study validates the numerical results with experimental study.

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 CHAPTER-3

ACTUAL WORK

Methodology of the study:

Figure 3: Methodology of the study

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Experimental and /or analytical work completed in the project:

1. Material:

Aluminum Alloy (6061) because of its high thermal conductivity, less density it is used
as material to fabricate the heat sink and it is cheaper compared to copper and nickel.
Since operation temperature is very less aluminum alloy is used rather than copper and
nickel.

2. Dimensions and Cutting:

The aluminum alloy sheet of dimensions 145 X 1250 mm (thickness of 3mm) is used
to design fins of dimensions 70 X 30 mm. filing is done for fins to smoothen the edges.
An angle grinding machine to remove the excess material of fins. Three Aluminum
alloy cylindrical blocks of diameter= 60 mm and height =70 mm with a hole of a
diameter=30 mm are designed. A heater is inserted into the cylinder to provide heat to
the heatsink. The height of the heater is equal to the height of the cylinder.

Figure 3.2: Heater

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 Figure 3.3: Cylinder with a hole and fins

3. Experimental Setup:

The experimental setup contains a rectangular frame at the center which is shown in the
figure holds Heats sink (Cylinder with fins) with the help of two supporting blocks.
The supporting blocks are also made up of CPVC pipes. The heater is placed inside the
cylinder. An insulator is placed between supporting blocks and the heatsink to avoid
heat loss into supporting blocks. Thermocol is placed between the heat sink and wood
to know the heat loss through the top and bottom of the heat sink. The frame is built
from CPVC pipes. This CPVC pipe stand is strong and rigid enough to hold the heat
sink. This frame can be tilted into desired angles based on the requirement and which
enables to measure the heat transfer at different orientations.

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Figure 3.4: Frame

4. Components and Connections:

AC type Voltmeter, Ammeter are the components used to measure the voltage and
current across the circuit and a handheld thermocouple with two probes is used to
measure the temperature at the surface, top, and bottom of the cylinder. Dimmerstat is
used to regulate the temperature as per the requirement. The output of Dimmerstat is 1-
3 amp.

Specifications of components used:

Heater:
Diameter: 28mm.
Height : 7cm.
Range : 5-250W

Voltmeter:
Range : 0-20AAC
Display : 20.00A
Aux.Supply: 230VAC

Ammeter:
Range : 0-20AAC
Display : 20.00A

Dimmerstat:
Range: 1-3 amp

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 A voltmeter is connected in series and ammeter is connected in parallel in the circuit.
The negative of the ammeter is connected to the load (heater). The other end of the
heater is connected to negative off Dimmerstat. The negative of the voltmeter is
connected to the negative of Dimmerstat. Initially when the load is not connected the
ammeter reading shows as '0'.
Figure 3.5: Circuit Diagram

Figure 3.6: Wood Box containing measuring components and connections

4. Sticking of Plate Fins to the Cylinder:

Fevikwik 203 and Metlok 743 are used to stick the fins on the cylinder. Both Fevikwik
and Metlok are cyanoacrylate adhesives that are applied to attach metal with metal.
These adhesives have service temperature ranges from 70-120 degrees Celsius which
is relatively high compared to the operations temperature. The fins which are attached
to the cylinder are free from air gaps. Heatsinks with three different number of fins
were fabricated to validate the simulation results, one is for an optimum number of fins,
and the other two are below and above the optimal.

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Figure 3.7: Sticking of fins

Figure 3.8: Adhesives used to stick the fins to the cylinder

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CAD model and Existing simulation results:

Figure 3.9: CAD model of Heatsink with Number of Fins =16

Figure 3.11: CAD model of Heatsink with Number of Fins = 30

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 Figure 3.11: CAD model of Heatsink with Number of Fins = 40

Ansys Fluent is the CFD tool used for simulation. The above figure shows the Computational
Domain.

Figure 3.12: Computational Domain

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As the number of fins increases the angle between two fins changes accordingly to know it an
equation is derived for the numerical analysis.

ϴ = 2 sin-1 (t/2r)
Where ϴ= Angle between two successive fins
t= Thickness of Fin
r= Outer radius of the cylinder

Figure 3.13: Existing Simulation Results

Prototype and testing:

Heatsink with optimum number of fins is tested. Initially the base temperature is
maintained at 35degree Celsius more than the room temperature (27degree
Celsius) till the heat sink reaches a steady state.
A power source of 30 W is supplied to the heatsink and using thermocouples the
base temperature and the upper tip of the fin temperature has been checked for
even distribution of temperature throughout the heatsink, then the heat sink has
been inserted into the frame using wood as an insulator and thermocol .Thermocol
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with known thermal conductivity of 0.0342 W/mC has been used. Using
thermocouple the temperature at the upper surface of the thermocol has been
observed and noted as temperature (T1) and the lower surface temperature of
thermocol (T2) has been assumed to be same as the base temperature .It has been
observed that the temperature difference (T2-T1) has been less than 5 degree
Celsius.

Figure 3.14: Block Diagram of the heater and supporting blocks

Figure 3.15: Testing of Heatsink

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 Figure 3.16: Reading after attaining Steady-state

Theoretical Calculations:

Fourier Heat Transfer Conduction Equation,

Q=K*A*dT/dx (dT=T2-T1)

Where
T2 = base temperature of cylinder = 62 degree Celsius
T1 = upper surface of thermocol disc = lower surface of thermocol disc = 58 degree Celsius
dx = thickness of the disc =2.1cm=0.021m
K = thermal conductivity of thermocol = 0.0314w/m degree Celsius
Q total = V*I – 2*Q (loss through thermocol)

Where V = voltage in volts

I = current in amps
Q total = total heat dissipated

Q (loss through thermocol) = K*A*dT/dx

= 0.0314*T1 (0.03)2*(62-58)/0.021
= 0.0314*π (0.03)2*(4/0.021)
= 0.01686w
Q total = V*I – Q loss
= (76*0.39)-0.01686
= 29.60314 W

h = Heat transfer co-efficient (convective)

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Q Total = h*A*dT

Area = Area of fins + Area of base

= (2HL+2Ht+Lt) + (ΠDL-nLt)
= (2*0.03*0.07) + (2*0.03*0.003) + (0.07*0.003) + (π*0.06*0.07-30*0.07*0.003)
= 0.01148 m2

h = (Q Total/A)*dT
= 29.90/0.01148*277
h = 9.3082 W/m2k

Conclusion:
The values which are obtained by experimental study are almost equal to the
Existing simulation results for optimum number of fins for maximum heat
transfer rate.

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REFERENCES:

[1] Yazicioğlu, B., and H.Yüncü, “optimum fins spacing of rectangular fins on a vertical base
in free convection heat transfer,” Turkey: Springer-Verlag, 2006.

[2] Jubear AJ, Al-Hamadani AA, “The effect of fin height on free convection heat transfer from
rectangular fin array,” Kut-wasit-Iraq: International Journal of Recent Scientific Research
2015.

[3] Bouknadel A, Rah I, El Omari H, El Omari H, “Comparative study of fin geometries for
heat sinks in natural convection,” Morocco: International Renewable and Sustainable Energy
Conference (IRSEC) (pp. 723-728) 2014.

[4] Kim, H.J., An, B.H., Park, J. and Kim, D.K, “Experimental study on natural convection
heat transfer from horizontal cylinders with longitudinal plate fins,” Korea: KSME & Springer
2013.

[5] Arefin, Amit Md Estiaque, “Thermal analysis of modified pin fin heat sink for natural
convection,” Bangladesh: 5th International Conference on Informatics, Electronics and Vision
(ICIEV) 2016.

[6] Jones, Charles D., and Lester F. Smith, “Optimum arrangement of rectangular fins on
horizontal surfaces for free-convection heat transfer,” Columbus: The American Society of
Mechanical Engineering (ASME), 1970.

[7] Shen, Q., Sun, D., Xu, Y., Jin, T., Zhao, X., Zhang, N., ... & Huang, Z, “Natural convection
heat transfer along vertical cylinder heat sinks with longitudinal fins,” PR China: International
Journal of Thermal Sciences, 100, 457-464, 2016.

[8] Shen, Qie, et al, “Orientation effects on natural convection heat dissipation of rectangular
fin heat sinks mounted on LEDs,” PR China: International Journal of Heat and mass
transfer 75 (462-469), 2014.

[9] Dewan, A., et al, “The effect of fin spacing and material on the performance of a heat sink
with circular pin fins,” Assam: Journal of Power and Energy 224.1 (35-46), 2010.

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