Heat transfer enhancement using the passive method of surface enhancers in microchannel heat sinks (MCHS) is always accompanied by increase in pressure drop and pumping power requirement. To reduce the pressure drop, a novel method of surface refinement is being proposed by transforming the ribs like surface enhancers to streamlined structures of the same cross-section. The performance of MCHS with and without surface refinement has been compared by evaluating pressure drop, Nusselt number and thermal enhancement factor for Reynolds number in the range of 100–1,000. The coning action of ribs results in a tremendous reduction in pressure drop with a negligible reduction in heat transfer thus, leading to a higher thermal enhancement factor for cones than ribs. Moreover, the performance improvement of various refined surfaces has been evaluated by computing percentage changes in pressure drop, Nusselt number, and thermal enhancement factor. Among all the cases, the surface refinement of the ribs has resulted in a maximum pressure drop reduction of 85% whereas the maximum reduction in Nusselt number is 25%; thereby achieving a thermal enhancement factor of 80%. The proposed surface refinement is expected to enhance the thermo-hydraulic characteristics as well as the energy consumptions of future generations of microelectronics.

The present study investigates the thermo-hydraulic characteristics of a microchannel sink with novel trefoil Shaped ribs. The motivation for this form of rib shape is taken from the design of lung alveoli that exchange oxygen and carbon dioxide. This study has been conducted numerically by using a code from the commercially available Fluent software. The trefoil shaped ribs were mounted on the centerline of different walls of the microchannel in three different configurations. These consisted of base wall trefoil ribs (MC-BWTR), sidewall trefoil ribs (MC-SWTR), all wall trefoil ribs (MC-AWTR) and smooth channel (MC-SC) having no ribs on its wall. The streamline distance between the ribs was kept constant at 0.4 mm, and the results were compared by using pressure drop (∆p), Nusselt number (Nu), thermal resistance (R_th) and thermal enhancement factor (η). The results indicated that the addition of trefoil ribs to any wall improved heat transfer characteristics at the expense of an increase in the friction factor. The trends of the pressure drop and heat transfer coefficient were the same, which indicated higher values for MC-AWTR followed by MC-SWTR and a lower value for MC-BWTR. In order to compare the thermal and hydraulic performance of all the configurations simultaneously, the overall performance was quantified in terms of the thermal enhancement factor, which was higher than one in each case, except for MC-AWTR, in 100 < Re < 200 regimes. The thermal enhancement factor in the ribbed channel was the highest for MC-SWTR followed by MC-BWTR, and it was the lowest for MC-AWTR. Moreover, the thermal enhancement factor increases with the Reynolds number (Re) for each case. This confirms that the increment in the Nusselt number with velocity is more significant than the pressure drop. The highest thermal enhancement factor of 1.6 was attained for MC-SWTR at Re = 1000, and the lowest value of 0.87 was achieved for MC-AWTR at Re = 100.

In the present study, conjugate heat transfer and fluid flow performance of microchannel heat sink has been investigated using dimensionless parameters. Novel ribs of four different types are introduced on the side walls of channel, which include trapezoidal ribs, rectangular ribs, hydrofoil ribs, and elliptical ribs. The performance evaluation has been conducted by comparing friction factor (f), Nusselt number ( N u Nu ), fluid bulk temperature ( T f {T_{f}} ), wall shear stress (τ), field synergy number ( F c Fc ), irreversible heat loss ( Q d {Q_{d}} ), and Bejan number ( B e Be ) in a Reynolds number, ranging from Re = 100 \mathit{Re}=100 to Re = 1000 \mathit{Re}=1000 . The results revealed that the addition of these novel ribs are helpful in improving the overall thermal and hydraulic performance of microchannel heat sink. From the results of Bejan number, it has been revealed that more than 96 % of losses are because of heat transfer. However, at low Reynolds number, the frictional losses can be neglected, because of very low fluid velocity. Moreover, it has been revealed that synergetic relation between velocity and temperature gradient becomes weaker at higher Reynolds number. Furthermore, it is clear from this study that elliptical ribs performed better in thermal aspects, whereas hydrofoil ribs performed better at hydrodynamic aspects.