From Pareto Optimization to Deployable Cold Plates: Design Correlation, Parameter Sensitivity, and Engineering Implementation of a Hybrid Microchannel Heat Sink

Multi-objective optimization studies of microchannel heat sinks (MCHS) frequently report peak performance at a single operating point without addressing the engineering questions that govern deployment: how robust is the optimal geometry, can performance be predicted without further CFD, which parameters truly drive the trade-off, and how can the design be manufactured and scaled. This paper bridges that gap for a hybrid MCHS combining oblique micro-grooves with a circular micro pin-fin array, optimized through a A-simulation CFD-driven MOGA-II (NSGA-II-based) campaign over Rev. The optimal designs converge to a robust window (Wg,VY mm, L₁ = ۹,۱ mm, ۰ = TA-TO, Dp, ) mm), achieving a thermo-hydraulic performance index of n = ۱, ۹۱, ۱, a Y_۹% Nusselt number enhancement, and a ۱.-۱.% pressure-drop reduction relative to the straight-channel baseline. A compact predictive correlation for n is developed and validated (R۲,۹A, mean error ۱,۹%), and a data-driven sensitivity analysis identifies groove width as the dominant driver of n (VA % global importance) and pin-fin diameter as the principal hydraulic lever (۲۰%). The paper concludes with manufacturing-feasibility considerations, a comparison with recent state-of-the-art studies, and a four-step implementation pathway toward industrial cold plates for power electronics, data-center, and aerospace thermal management.

کلیدواژه ها:

Cold plate design ، Design correlation ، Parameter sensitivity ، Manufacturing feasibility ، Thermal management