Case Study

Weight Optimization and Structural Enhancement of High-Pressure Cold Plates using CFD and CAE Tools

Introduction

The Alkraft design team was requested by a customer to work on a project to design and develop a high-pressure cold plate. The team came up with an initial design, but the customer requested a further weight reduction, which led to an iterative design and optimization process to reduce product weight while maintaining thermal performance, structural rigidity, and durability.

Project Overview

Cold Plate 2
(
Top Plate
"
Inlet Port
%
Outlet Port
%
Middle Plate
%
Bottom Plate
Cold Plate 1
(
Wall Heat Flux applied to this area at the Base

The primary objective of this project was to optimize the design of a high-pressure cold plate to reduce its weight by 20% without compromising its structural and thermal performance. The process involved improving and enhancing the geometrical parameters through CFD and CAE simulations.

Design and Optimization Process

Initial Design

Weight
Coolant Pressure Drop
Maximum Temperature at Base Plate
Maximum Temperature Variation at Base Plate
Coolant Flow Rate
Maximum Coolant Temperature
Displacement at Static Pressure (10 bar)
7.1 kg
94 kPa
19.1oC
3.5oC
14.8 LPM
19oC
0.02 mm

Simulation Tools and Methodology

The optimization process was carried out using ANSYS Fluent for CFD simulations and structural analysis tools for CAE. The simulations helped in understanding the impact of geometrical changes on thermal and structural performance.

Thermal Design Optimization

Initial Design

Initial Design

Improved Design

Improved Design
Base Plate Heat Flux
Coolant Inlet Temperature
8500 W/m²
15oC

The improved design maintained the same temperature variation in the base plate as the initial design by optimizing the geometrical parameters. This was achieved without compromising the structural rigidity and durability of the product.

Structural Design Optimization

The displacement and stress values in the improved design were found to be less than those in the initial design, indicating enhanced structural integrity.

Initial Design
Improved Design
Displacement Contours
Stress Contours

Benchmarking Design Parameters

Initial Design
Improved Design
Weight
7.1 kg
5.8 kg
Coolant Pressure Drop
94 kPa
104 kPa
Maximum Temperature at Base Plate
19.1oC
19.2oC
Maximum Temperature Variation at Base Plate
3.5oC
3.5oC
Coolant Flow Rate
14.8 LPM
14.1 LPM
Maximum Coolant Temperature
19oC
19.1oC
Displacement at Static Pressure (10 bar)
0.02 mm
0.01 mm

Comparative Results

Thermal Performance

    • The maximum temperature at the base plate and the temperature variation remained consistent between the initial and improved designs.
    • The coolant pressure drop increased slightly from 94 kPa to 104 kPa, which is within acceptable limits.
    • The coolant flow rate saw a minor reduction from 14.8 LPM to 14.1 LPM.
    • The maximum coolant temperature saw a negligible increase from 19°C to 19.1°C.

Structural Performance

    • The displacement at static pressure of 10 bar reduced from 0.02 mm to 0.01 mm in the improved design.
    • Stress contours indicated a decrease in stress values in the improved design compared to the initial design.

Conclusion

By leveraging CFD and CAE tools, Alkraft successfully optimized the high-pressure cold plate design to achieve a 20% weight reduction while maintaining the required thermal performance and enhancing structural rigidity and durability. The iterative design process ensured that all critical parameters were met, providing a robust and efficient solution for the customer.
Alkraft’s approach to optimizing the high-pressure cold plate exemplifies its commitment to innovation and excellence in thermal management solutions. This case study underscores the importance of advanced simulation tools in optimizing product designs, enabling significant improvements in performance and efficiency, and the critical roles these tools play in Alkraft’s design and product development processes.

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