This study concerns the geometric design of a cylindrical micropin-fin heat sink with multiple row configurations. The objective is to maximize the rate of heat transfer from the solid to the fluid subject to total fin volume and manufacturing constraints. A heat sink with dimensions of 1 mm × 0.6 mm × 1 mm is used for the computational analysis. An automated gradient-based optimization algorithm, which effectively handles an objective function obtained from a computational fluid dynamics simulation is implemented. The optimal design is obtained as results of balance of conductive heat transfer along the pin-fins with laminar forced convection. In the first case, the fins are arranged in two rows of pin-fins with different geometric sizes (diameter, height, and spacing between the fins). The optimal configurations obtained as a function of thermal conductivity ratio and Reynolds number are found to be in good agreement with those obtained from theory and numerical optimization. In the second case, the fins are arranged in rows of three, the effect of thermal conductivity and Reynolds number on the optimal configuration and the maximized heat transfer rate from the arrays of cylinders is reported.

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