Experimental and Numerical Investigation of Heat Transfer Augmentation using Symmetrical Dual Sinusoidal Copper Fins in a Rectangular Duct

The enhancement of heat transfer through optimally designed heat sinks is crucial for improving the performance and extending the operational lifespan of heat-generating devices. This study investigates the thermal and fluid flow behaviour of an innovatively developed heat sink featuring symmetrical dual sinusoidal shape fins (DSSF), using both experimental and numerical approaches. A detailed three-dimensional (3D) computational model was constructed to simulate the system’s performance. The friction factor (f) was estimated using Blasius’s correlation, and the Nusselt number (Nu) was determined using the Dittus–Boelter correlation. Simulated outcomes were validated against experimental data collected from a purpose-built test rig operating under identical conditions, with a uniform heat flux of 2413 W/m². The results exhibited strong agreement, with average deviations limited to 7.45% for the f and 15.22% for the Nu. The best performance was achieved at a Reynolds number (Re) of 3000, where the system performance evaluation criteria (SPEC) reached 1.734, indicating that heat transfer enhancement outweighed the pumping power requirements. The deviation between computational and experimental SPEC remained within 10.89%. Compared to conventional designs, the DSSF heat sink demonstrated significantly improved thermal performance – achieving a 57.96% higher Nu than square-shaped fins and a 28.11% increase over diamond-shaped fins. These findings confirm the superior cooling efficiency of the DSSF configuration, making it a promising solution for compact and efficient thermal management in heat-generating electronic systems.