In recent years, manufacturing technologies have advanced, and producing parts with complex geometries is now possible. For example, a proper cooling system must be designed when casting is used in production of geometrically intricate component. An excellent example of a complex component to be manufactured are the heat sinks used in electric vehicles. Nevertheless, in this area of activity optimizing thermal dissipation is vital. Reducing component mass is also crucial for overall vehicle performance. Heat sink geometry and mass are key factors determining their heat transfer properties. In this context, the present study aims to explore the impact of heat sink geometry and mass on its heat transfer properties. Results showed that the heat sink’s mass can be reduced by 27 % while its thermal dissipation properties being improved. Also, the trapezoidal fin geometry is more effective in dissipating heat, leading to a 30% increase in the heat transfer coefficient of the heat sink at 50°C and a 36% increase at 90°C when compared to rectangular fins. The findings of this study can provide valuable insights for the improvement of the foundry design of this component, taking into account these critical factors.

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