Investigation of Structure-Performance Relationship of Heat Exchanger using Topology Optimization

Heat exchangers often face challenges such as uneven flow distribution, low heat transfer efficiency, and excessive pressure loss, which hinder energy utilization and operational performance. To address these issues, this study employs topology optimization and parameter optimization methods to enhance the flow and heat transfer performance of heat exchanger tube bundles. First, a shape sensitivity analysis is conducted to identify key regions influencing performance, revealing that the intervals of 60–100 and 260–300° exhibit the highest sensitivity. The topology-optimized structure demonstrates significant improvements, with a 6.40% increase in flow performance, a 0.63% enhancement in heat transfer efficiency, and a 7.54% boost in overall performance compared to the original structure with an average deformation of 0.05 mm. Parameter optimization, while yielding slightly lower performance gains, produces more regular and industrially feasible structures. The study highlights the advantages of topology optimization in exploring a broader design space without being constrained by predefined parameters, offering a more efficient approach to performance enhancement. By integrating sensitivity analysis and optimization techniques, this research provides theoretical guidance for the structural design of heat exchangers, contributing to improved energy efficiency and operational stability in industrial applications.