Multi-objective optimization of an innovative liquid-cooled micro-grooved heat sink by experimental, numerical and statistical approaches

Özbektaş S., Özbey M., Öztürk E., Şahin F.

INTERNATIONAL JOURNAL OF THERMAL SCIENCES, vol.225, 2026 (SCI-Expanded, Scopus)

Abstract

Today, high-performance electronic systems such as batteries, CPUs, and power electronic components generate large amounts of heat while operating. Micro-grooved heat sinks can play an important role in the cooling of these systems and provide compact, lightweight, and energy-efficient solutions that enable maximum heat transfer in a small volume. However, the existence of the grooves can cause an increase in the pressure losses and, hence, higher pumping power. In this context, it is essential to optimize the micro-grooved heat sink in terms of heat transfer and pressure loss. In this study, a liquid-cooled micro-grooved heat sink was thermally and hydrodynamically optimized simultaneously based on five factors, namely, angle with flow direction, groove type, groove width, groove depth, and distance between grooves. For this purpose, an L32 orthogonal array was created and modeled by Fluent, a CFD program. Optimal geometry was revealed by Grey Relational Analysis, an ANOVA approach, and manufactured by the micromachining method. It was determined that the angle with flow direction, groove width, and depth factors were statistically significant, with contribution percentages of 28.23%, 26.26%, and 34.31%, respectively. As a result, 0 degrees flow direction angle, trapezoidal groove type, 500 mu m groove width, 200 mu m groove depth, and 200 mu m distance between grooves were determined as optimal design parameters. Thermo-hydraulic efficiency, defined as the balance between heat transfer enhancement and hydraulic cost, was evaluated through the performance evaluation criterion (PEC), showing that the optimal microgrooved surface yields nearly a 40% improvement.