Thermal performance optimization of microchannel heat sinks with triangle wave fin designs and various heat transfer fluids using GA/RSM/TOPSIS

Microchannel heat sinks (MHSs) stand out as a promising solution for dissipating heat in high-performance systems. The development and optimization of these systems are vital to meeting the growing demands of modern, power-dense electronics. The present study introduces a novel approach to enhance heat dissipation in microchannel systems. The design incorporates two sets of fins with a distinctive triangle wave pattern within the microchannels. The acquired results for the introduced fins were compared with the data of a non-finned MHS and a device with straight fins. The maximum temperature of the non-finned MHS was 307.222 K, while the incorporation of the mentioned fins reduced the temperature by approximately 2 K. This reduction is significant, as lower maximum temperatures improve the reliability and longevity of electronic components. Response surface methodology (RSM) was utilized to develop predictive models, reducing reliance on complex simulations and costly prototypes. The effects of fin folding angle ( θ ) and spacing from side walls ( S ) on thermo-hydraulic performance were systematically analyzed. Optimization was achieved by integrating genetic algorithms with the predictive models. Three distinct optimization targets (maximizing the Nusselt number, minimizing the pressure drop, and maximizing the device’s overall efficiency) were considered, and three optimum designs were proposed for each target. Additionally, Pareto front analysis and TOPSIS evaluation provided a comprehensive multi-objective assessment. In RSM-based anticipation models, the R 2 values were 0.971 for the Nusselt number and 0.977 for pressure drop. The remarkable R 2 values indicated that the models for both responses had a high level of accuracy. Based on the results, heat sink design 3 (HSD3) with geometric parameters of θ =97.785° and S =70 μm was recommended for enhancing the overall performance of the MHS. By utilizing just two triangle wave fins configured according to the parameters of HSD3, the overall efficiency and Nusselt number of the MHS enhanced by approximately 8.7% and 43.86% compared to the non-finned MHS, respectively. The study further explored different heat transfer fluids within the HSD3, comparing their performance with water to identify the most effective cooling medium. Among the fluids analyzed, acetone and silicon oil demonstrated superior performance, resulting in an increase in the overall efficiency of HSD3 by approximately 138.4% and 134.6%, respectively, when used as coolant in place of water.