Topology optimization of channel cooling structures considering thermomechanical behavior

A topology optimization method is presented to design straight channel cooling structures for efficient heat transfer and load carrying capabilities. The optimization is performed on the structural cross section that consists of solid, void, and fluid coolant. A simplified convective heat transfer model is used to simulate the flow characteristic in the channels with a low computational cost. Besides, a continuous design-dependent surface-based penalty approach is proposed to ensure a meaningful inlet fluid temperature during the continuous process of the fluid topology alteration. Coupled thermomechanical problems are solved to account for the engineering requirements on the uniformity of temperature and structural deformation tolerance. Furthermore, a phase-interface constraint is implemented to prevent unrealistic boundaries that adjoin the liquid to the void or to the outer boundaries of a design domain. Numerical examples of designing a lightweight cooling support frame and a hot stamping tool structure subject to uniform or non-uniform thermomechanical loads are given to demonstrate its applicability. Verification results of 3D structures by a full-blown turbulent fluid simulation show that the proposed approach is effective in yielding channel cooling structures with optimized heat transfer capabilities and well-controlled structural deformation.