Abstract
This paper proposes a computational fluid dynamics (CFD) simulation methodology for the multi-design variable optimization of heat sinks for natural convection single-phase immersion cooling of high power-density Data Center server electronics. Immersion cooling provides the capability to cool higher power-densities than air cooling. Due to this, retrofitting Data Center servers initially designed for air-cooling for immersion cooling is of interest. A common area of improvement is in optimizing the air-cooled component heat sinks for the fluid and thermal properties of liquid cooling dielectric fluids. Current heat sink optimization methodologies for immersion cooling demonstrated within the literature rely on a server-level optimization approach. This paper proposes a server-agnostic approach to immersion cooling heat sink optimization by developing a heat sink-level CFD to generate a dataset of optimized heat sinks for a range of variable input parameters: inlet fluid temperature, power dissipation, fin thickness, and number of fins. The objective function of optimization is minimizing heat sink thermal resistance. This research demonstrates an effective modeling and optimization approach for heat sinks. The optimized heat sink designs exhibit improved cooling performance and reduced pressure drop compared to traditional heat sink designs. This study also shows the importance of considering multiple design variables in the heat sink optimization process and extends immersion heat sink optimization beyond server-dependent solutions. The proposed approach can also be extended to other cooling techniques and applications, where optimizing the design variables of heat sinks can improve cooling performance and reduce energy consumption.
