Thermal Performance Analysis and Multi-Objective Optimization Design of Heat Sinks Gate Structures Based on Numerical Simulation and Genetic Algorithms

Heat sinks for high-power devices are frequently manufactured via integral casting to ensure long-term stability and superior thermal performance. This study investigates the effects of the location, number, and arrangement of casting gates on heat transfer performance and temperature uniformity. The results indicate that positioning gates on the inlet side enhances heat transfer, whereas an outlet-side arrangement improves temperature uniformity. The 3-O configuration (casting gate diameter of 3 mm positioned at the front) was observed to exhibit the optimal hydrothermal performance factor (HTPF), achieving a maximum improvement of 32% compared to the benchmark 0-OMT (finned heat sink without gates). Meanwhile, the best temperature uniformity was demonstrated by the 5-M configuration (gate diameter of 5 mm positioned in the middle), with a maximum improvement of 64.8% over the benchmark. Furthermore, a power-law predictive model correlating the variables with the objective functions was established, and multi-objective optimization was conducted in conjunction with a Genetic Algorithm (GA). The results indicated that a significant enhancement in comprehensive performance was achieved by the optimized model; compared with the initial model, the temperature rise (ΔT) and pressure loss (ΔP) were reduced by 59.06% and 39.94%.