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Table of Contents
1. Using This Manual ................................................................................................................................... 1 1.1. What's In This Manual ........................................................................................................................ 1 1.2. How To Use This Manual .................................................................................................................... 1 1.2.1. For the Beginner ...................................................................................................................... 1 1.2.2. For the Experienced User .......................................................................................................... 1 1.3.Typographical Conventions Used In This Manual ................................................................................ 1 1.4. Mouse Conventions Used In This Manual ........................................................................................... 2 1.5. When To Call Your ANSYS Icepak Support Engineer ............................................................................ 2 2. Finned Heat Sink ..................................................................................................................................... 3 2.1. Introduction ..................................................................................................................................... 3 2.2. Prerequisites ..................................................................................................................................... 3 2.3. Problem Description ......................................................................................................................... 3 2.4. Step 1: Create a New Project .............................................................................................................. 4 2.5. Step 2: Build the Model ..................................................................................................................... 5 2.6. Step 3: Generate a Mesh .................................................................................................................. 18 2.7. Step 4: Physical and Numerical Settings ........................................................................................... 23 2.8. Step 5: Save the Model .................................................................................................................... 25 2.9. Step 6: Calculate a Solution ............................................................................................................. 25 2.10. Step 7: Examine the Results ........................................................................................................... 27 2.11. Step 8: Summary ........................................................................................................................... 35 2.12. Step 9: Additional Exercise ............................................................................................................. 36 3. RF Amplifier ........................................................................................................................................... 37 3.1. Introduction ................................................................................................................................... 37 3.2. Prerequisites ................................................................................................................................... 37 3.3. Problem Description ....................................................................................................................... 37 3.4. Step 1: Create a New Project ............................................................................................................ 38 3.5. Step 2: Build the Model ................................................................................................................... 39 3.6. Step 3: Create Assemblies ................................................................................................................ 53 3.7. Step 4: Generate a Mesh .................................................................................................................. 55 3.8. Step 5: Physical and Numerical Settings ........................................................................................... 58 3.9. Step 6: Save the Model .................................................................................................................... 61 3.10. Step 7: Calculate a Solution ........................................................................................................... 61 3.11. Step 8: Examine the Results ........................................................................................................... 63 3.12. Step 9: Summary ........................................................................................................................... 70 4. Use of Parameterization to Optimize Fan Location .............................................................................. 71 4.1. Introduction ................................................................................................................................... 71 4.2. Prerequisites ................................................................................................................................... 71 4.3. Problem Description ....................................................................................................................... 71 4.4. Step 1: Create a New Project ............................................................................................................ 72 4.5. Step 2: Build the Model ................................................................................................................... 72 4.6. Step 3: Creating Separately Meshed Assemblies ............................................................................... 83 4.7. Step 4: Generate a Mesh .................................................................................................................. 84 4.8. Step 5: Setting up the Multiple Trials ................................................................................................ 84 4.9. Step 6: Creating Monitor Points ....................................................................................................... 86 4.10. Step 7: Physical and Numerical Setting ........................................................................................... 87 4.11. Step 8: Save the Model .................................................................................................................. 88 4.12. Step 9: Calculate a Solution ........................................................................................................... 89 4.13. Step 10: Examine the Results ......................................................................................................... 90 4.14. Step 11: Reports ............................................................................................................................ 93 4.15. Step 12: Summary ......................................................................................................................... 93
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ANSYS Icepak Tutorials 4.16. Step 13: Additional Exercise to Model Higher Altitude Effect ........................................................... 93 5. Cold-Plate Model with Non-Conformal Meshing .................................................................................. 97 5.1. Introduction ................................................................................................................................... 97 5.2. Prerequisites ................................................................................................................................... 97 5.3. Problem Description ....................................................................................................................... 97 5.4. Step 1: Create a New Project ............................................................................................................ 97 5.5. Step 2: Build the Model ................................................................................................................... 97 5.6. Step 3: Create a Separately Meshed Assembly ................................................................................ 101 5.7. Step 4: Generate a Mesh ................................................................................................................ 102 5.8. Step 5: Physical and Numerical Settings ......................................................................................... 103 5.9. Step 6: Save the Model .................................................................................................................. 105 5.10. Step 7: Calculate a Solution .......................................................................................................... 105 5.11. Step 8: Examine the Results ......................................................................................................... 105 5.12. Step 9: Summary ......................................................................................................................... 106 5.13. Step 10: Additional Exercise ......................................................................................................... 106 6. Heat-Pipe Modeling and Nested Non-Conformal Meshing ................................................................ 107 6.1. Introduction ................................................................................................................................. 107 6.2. Prerequisites ................................................................................................................................. 107 6.3. Problem Description ..................................................................................................................... 107 6.4. Step 1: Create a New Project .......................................................................................................... 108 6.5. Step 2: Build the Model ................................................................................................................. 109 6.6. Step 3: Create Nested Non-conformal Mesh Using Assemblies ........................................................ 113 6.7. Step 4: Generate a Mesh ................................................................................................................ 115 6.8. Step 5: Physical and Numerical Settings ......................................................................................... 115 6.9. Step 6: Save the Model .................................................................................................................. 116 6.10. Step 7: Calculate a Solution .......................................................................................................... 117 6.11. Step 8: Examine the Results ......................................................................................................... 117 6.12. Step 9: Summary ......................................................................................................................... 119 7. Non-Conformal Mesh .......................................................................................................................... 121 7.1. Introduction ................................................................................................................................. 121 7.2. Prerequisites ................................................................................................................................. 121 7.3. Problem Description ..................................................................................................................... 121 7.4. Step 1: Create a New Project .......................................................................................................... 122 7.5. Step 2: Build the Model ................................................................................................................. 122 7.6. Step 3: Generate a Conformal Mesh ............................................................................................... 124 7.7. Step 4: Physical and Numerical Settings ......................................................................................... 125 7.8. Step 5: Save the Model .................................................................................................................. 126 7.9. Step 6: Calculate a Solution ........................................................................................................... 126 7.10. Step 7: Examine the Results ......................................................................................................... 126 7.11. Step 8: Add an Assembly to the Model ......................................................................................... 127 7.12. Step 9: Generate a Non-conformal Mesh ...................................................................................... 129 7.13. Step 10: Save the Model .............................................................................................................. 130 7.14. Step 11: Calculate a Solution ........................................................................................................ 130 7.15. Step 12: Examine the Results ....................................................................................................... 131 7.16. Step 13: Summary ....................................................................................................................... 131 8. Mesh and Model Enhancement Exercise ............................................................................................. 133 8.1. Objective ...................................................................................................................................... 133 8.2. Prerequisites ................................................................................................................................. 133 8.3. Skills Covered ............................................................................................................................... 133 8.4. Training Method Used ................................................................................................................... 133 8.5. Loading the Model ........................................................................................................................ 133 8.6. A 15 Minute Exploration ................................................................................................................ 133
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ANSYS Icepak Tutorials 8.7. Step-by-Step Approach ................................................................................................................. 134 8.8. Modification 1: Non-Conformal Mesh of the Heat Sink and Components ........................................ 135 8.9. Modification 2: Resolution of Thin Conducting Plate Intersecting Non-Conformal Region ................ 137 8.10. Modification 3: Non-Conformal Mesh for the hi-flux-comps Cluster .............................................. 137 8.11. Modification 4: A Super Assembly... .............................................................................................. 138 8.12. Modification 5: A Simplification Based on Magnitudes of Resistances... ......................................... 140 8.13. Modification 6: A Classic Case for Thin Conducting Plate... ............................................................ 140 8.14. Conclusion .................................................................................................................................. 141 9. Loss Coefficient for a Hexa-Grille ........................................................................................................ 143 9.1. Introduction ................................................................................................................................. 143 9.2. Prerequisites ................................................................................................................................. 143 9.3. Problem Description ..................................................................................................................... 143 9.4. Step 1: Create a New Project .......................................................................................................... 144 9.5. Step 2: Build the Model ................................................................................................................. 144 9.6. Step 3: Define Parameters and Trials ............................................................................................... 146 9.7. Step 4: Generate a Mesh ................................................................................................................ 153 9.8. Step 5: Physical and Numerical Settings ......................................................................................... 154 9.9. Step 6: Save the Model .................................................................................................................. 155 9.10. Step 7: Calculate a Solution .......................................................................................................... 155 9.11. Step 8: Examine the Results ......................................................................................................... 155 9.12. Step 9: Summary ......................................................................................................................... 156 10. Inline or Staggered Heat Sink ........................................................................................................... 157 10.1. Introduction ............................................................................................................................... 157 10.2. Prerequisites ............................................................................................................................... 157 10.3. Problem Description ................................................................................................................... 157 10.4. Step 1: Create a New Project ........................................................................................................ 158 10.5. Step 2: Build the Model ................................................................................................................ 159 10.6. Step 3: Define Design Variables .................................................................................................... 160 10.7. Step 4: Define Parametric Runs and Assign Primary Functions ...................................................... 162 10.8. Step 5: Generate a Mesh .............................................................................................................. 165 10.9. Step 6: Physical and Numerical Settings ....................................................................................... 166 10.10. Step 7: Save the Model .............................................................................................................. 166 10.11. Step 8: Define Monitor Points ..................................................................................................... 166 10.12. Step 9: Calculate a Solution ........................................................................................................ 166 10.13. Step 10: Examine the Results ...................................................................................................... 167 10.14. Step 11: Summary ..................................................................................................................... 172 11. Minimizing Thermal Resistance ........................................................................................................ 173 11.1. Introduction ............................................................................................................................... 173 11.2. Prerequisites ............................................................................................................................... 173 11.3. Problem Description ................................................................................................................... 173 11.4. Step 1: Create a New Project ........................................................................................................ 174 11.5. Step 2: Build the Model ................................................................................................................ 174 11.6. Step 3: Define Design Variables .................................................................................................... 175 11.7. Step 4: Generate a Mesh .............................................................................................................. 177 11.8. Step 5: Physical and Numerical Settings ....................................................................................... 178 11.9. Step 6: Save the Model ................................................................................................................ 178 11.10. Step 7: Define Primary, Compound, and Objective Functions ....................................................... 178 11.11. Step 8: Calculate a Solution ........................................................................................................ 180 11.12. Step 9: Examine the Results ....................................................................................................... 181 11.13. Step 10: Summary ..................................................................................................................... 182 11.14. Step 11: Additional Exercise ....................................................................................................... 182 12. Radiation Modeling .......................................................................................................................... 185
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ANSYS Icepak Tutorials 12.1. Introduction ............................................................................................................................... 185 12.2. Prerequisites ............................................................................................................................... 185 12.3. Problem Description ................................................................................................................... 185 12.4. Step 1: Create a New Project ........................................................................................................ 185 12.5. Step 2: Build the Model ................................................................................................................ 185 12.6. Step 3: Generate a Mesh .............................................................................................................. 191 12.7. Step 4: Physical and Numerical Settings ....................................................................................... 193 12.8. Step 5: Solving the Model Without Radiation ................................................................................ 193 12.9. Step 6: Save the Model ................................................................................................................ 196 12.10. Step 7: Calculate a Solution- No Radiation .................................................................................. 196 12.11. Step 8: Surface to Surface (S2S) Radiation Model ........................................................................ 196 12.12. Step 9: Discrete Ordinates (DO) Radiation Model ........................................................................ 197 12.13. Step 10: Ray Tracing Radiation Model ......................................................................................... 197 12.14. Step 11: Examine the Results ...................................................................................................... 197 12.15. Step 12: Summary ..................................................................................................................... 200 13. Transient Simulation ......................................................................................................................... 201 13.1. Introduction ............................................................................................................................... 201 13.2. Prerequisites ............................................................................................................................... 201 13.3. Problem Description ................................................................................................................... 201 13.4. Step 1: Create a New Project ........................................................................................................ 201 13.5. Step 2: Build the Model ................................................................................................................ 202 13.6. Step 4: Generate a Mesh .............................................................................................................. 206 13.7. Step 5: Physical and Numerical Settings ....................................................................................... 206 13.8. Step 6: Save the Model ................................................................................................................ 207 13.9. Step 7: Calculate a Solution .......................................................................................................... 207 13.10. Step 8: Generate a Summary Report ........................................................................................... 207 13.11. Step 9: Examine the Results ....................................................................................................... 208 13.12. Step 10: Examine Transient Results in CFD Post ........................................................................... 210 13.13. Step 10: Summary ..................................................................................................................... 215 14. Zoom-In Modeling in ANSYS Workbench .......................................................................................... 217 14.1. Introduction ............................................................................................................................... 217 14.2. Prerequisites ............................................................................................................................... 217 14.3. Problem Description ................................................................................................................... 217 14.4. Step 1: Create a New Project ........................................................................................................ 218 14.5. Step 2: Build the Model ................................................................................................................ 219 14.6. Step 3: Generate a Mesh .............................................................................................................. 220 14.7. Step 4: Physical and Numerical Settings ....................................................................................... 221 14.8. Step 5: Save the Model ................................................................................................................ 222 14.9. Step 6: Calculate a Solution .......................................................................................................... 222 14.10. Step 7: Examine the Results ....................................................................................................... 222 14.11. Step 8: Create a Zoom-In Model ................................................................................................. 224 14.12. Step 9: Edit the Zoom-in Model .................................................................................................. 226 14.13. Step 10: Mesh the Zoom-In Model ............................................................................................. 228 14.14. Step 11: Zoom-In Physical and Numerical Settings ...................................................................... 229 14.15. Step 12: Examine the Zoom-in Results ........................................................................................ 229 14.16. Step 13: Summary ..................................................................................................................... 231 14.17. Step 14: Additional Exercise 1 .................................................................................................... 231 14.18. Step 15: Additional Exercise 2 .................................................................................................... 232 15. IDF Import ......................................................................................................................................... 235 15.1. Introduction ............................................................................................................................... 235 15.2. Prerequisites ............................................................................................................................... 235 15.3. Problem Description ................................................................................................................... 235
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ANSYS Icepak Tutorials 15.4. Step 1: Create a New Project ........................................................................................................ 235 15.5. Step 2: Build the Model ................................................................................................................ 236 15.6. Step 3: Component Filtration Alternatives .................................................................................... 240 15.7. Step 4: Component Models Alternatives ...................................................................................... 241 15.8. Step 5: Summary ......................................................................................................................... 242 16. Modeling CAD Geometry .................................................................................................................. 245 16.1. Introduction ............................................................................................................................... 245 16.2. Prerequisites ............................................................................................................................... 245 16.3. Problem Description ................................................................................................................... 245 16.4. Step 1: Creating a New Project ..................................................................................................... 246 16.5. Step 2: Build the Model ................................................................................................................ 247 16.6. Step 3: Generate a Mesh .............................................................................................................. 255 16.7. Step 4: Physical and Numerical Settings ....................................................................................... 258 16.8. Step 5: Save the Model ................................................................................................................ 261 16.9. Step 6: Calculate a Solution .......................................................................................................... 262 16.10. Step 7: Examine the Results ....................................................................................................... 263 16.11. Step 8: Summary ....................................................................................................................... 265 17. Trace Layer Import for Printed Circuit Boards ................................................................................... 267 17.1. Introduction ............................................................................................................................... 267 17.2. Prerequisites ............................................................................................................................... 267 17.3. Problem Description ................................................................................................................... 268 17.4. Step 1: Create a New Project ........................................................................................................ 268 17.5. Step 2: Build the Model ................................................................................................................ 268 17.6. Conduction Only Model (PCB Without the Components) .............................................................. 276 17.7. Step 1: Generate a Mesh .............................................................................................................. 276 17.8. Step 2: Set Physical and Numerical Values .................................................................................... 277 17.9. Step 3: Save the Model ................................................................................................................ 277 17.10. Step 4: Calculate a Solution ........................................................................................................ 277 17.11. Step 5: Examine the Results ....................................................................................................... 278 17.12. PCB With the Actual Components Under Forced Convection ...................................................... 279 17.13. Step 1: Generate a Mesh ............................................................................................................ 279 17.14. Step 2: Set Physical and Numerical Values .................................................................................. 280 17.15. Step 3: Calculate a Solution ........................................................................................................ 280 17.16. Step 4: Examine the Results ....................................................................................................... 280 17.17. Using the Model Layers Separately Option ................................................................................. 281 17.18. Summary .................................................................................................................................. 282 17.19. Additional Exercise 1 ................................................................................................................. 282 17.20. Additional Exercise 2 ................................................................................................................. 282 18. Joule/Trace Heating .......................................................................................................................... 283 18.1. Introduction ............................................................................................................................... 283 18.2. Prerequisites ............................................................................................................................... 283 18.3. Problem Description ................................................................................................................... 283 18.4. Step 1: Create a New Project ........................................................................................................ 283 18.5. Step 2: Build the Model ................................................................................................................ 284 18.6. Step 3: Generate a Mesh .............................................................................................................. 289 18.7. Step 4: Physical and Numerical Settings ....................................................................................... 290 18.8. Step 5: Save the Model ................................................................................................................ 291 18.9. Step 6: Calculate a Solution .......................................................................................................... 291 18.10. Step 7: Examine the Results ....................................................................................................... 291 18.11. Step 8: Summary ....................................................................................................................... 294 19. Microelectronics Packages - Compact models .................................................................................. 295 19.1. Introduction ............................................................................................................................... 295
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ANSYS Icepak Tutorials 19.2. Prerequisites ............................................................................................................................... 295 19.3. Problem Description ................................................................................................................... 295 19.4. Step 1: Create a New Project ........................................................................................................ 296 19.5. Step 2: Build the Model ................................................................................................................ 296 19.6. Step 3: Generate a Mesh .............................................................................................................. 305 19.7. Step 4: Physical and Numerical Settings ....................................................................................... 306 19.8. Step 5: Save the Model ................................................................................................................ 307 19.9. Step 6: Calculate a Solution .......................................................................................................... 307 19.10. Step 7: Examine the Results ....................................................................................................... 309 19.11. Step 8: Summary ....................................................................................................................... 310 19.12. Step 9: Additional Exercise ......................................................................................................... 310 20. Multi-Level Meshing .......................................................................................................................... 311 20.1. Objective .................................................................................................................................... 311 20.2. Prerequisites ............................................................................................................................... 311 20.3. Skills Covered .............................................................................................................................. 311 20.4. Training Method Used ................................................................................................................. 311 20.5. Loading the Model ...................................................................................................................... 311 20.6. Step-by-Step Approach ............................................................................................................... 311 20.7. Modification 1: Multi-Level Meshing of the Fan_Guide ................................................................. 314 20.8. Modification 2: Multi-Level Mesh of the Sheetmetal_hs_assy.1 ..................................................... 315 20.9. Generate a Mesh ......................................................................................................................... 316 20.10. Conclusion ................................................................................................................................ 319 21. Characterizing a BGA-package by Utilizing ECAD Files .................................................................... 321 21.1. Introduction ............................................................................................................................... 321 21.2. Prerequisites ............................................................................................................................... 321 21.3. Problem Description ................................................................................................................... 321 21.4. Step 1: Create a New Project ........................................................................................................ 321 21.5. Step 2: Build the Model ................................................................................................................ 321 21.6. Step 3: Generate a Mesh .............................................................................................................. 325 21.7. Step 4: Physical and Numerical Settings ....................................................................................... 326 21.8. Step 5: Save the Model ................................................................................................................ 327 21.9. Step 6: Calculate a Solution .......................................................................................................... 327 21.10. Step 7: Examine the Results ....................................................................................................... 327 21.11. Step 8: Summary ....................................................................................................................... 329 22. Zero Slack with Non-Conformal Meshing ......................................................................................... 331 22.1. Introduction ............................................................................................................................... 331 22.2. Prerequisites ............................................................................................................................... 331 22.3. Problem Description ................................................................................................................... 331 22.4. Step 1: Create a New Project ........................................................................................................ 333 22.5. Step 2: Default Units .................................................................................................................... 333 22.6. Step 3: Build the Model ................................................................................................................ 333 22.7. Step 4: Import Traces ................................................................................................................... 333 22.8. Step 5: Add Slack Values .............................................................................................................. 334 22.9. Step 6: Generate Mesh (with Slack Values) .................................................................................... 335 22.10. Step 7: Zero Slack ...................................................................................................................... 336 22.11. Step 8: Generate Mesh (with Zero Slack) ..................................................................................... 337 22.12. Step 9: Physical and Numerical Settings ..................................................................................... 337 22.13. Step 10: Save the Model ............................................................................................................. 338 22.14. Step 11: Calculate a Solution ...................................................................................................... 338 22.15. Step 12: Examine the Results ...................................................................................................... 338 22.16. Step 13: Summary ..................................................................................................................... 338 23. ANSYS Icepak - ANSYS Workbench IntegrationTutorial ................................................................... 339
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ANSYS Icepak Tutorials 23.1. Introduction ............................................................................................................................... 339 23.2. Prerequisites ............................................................................................................................... 339 23.3. Problem Description ................................................................................................................... 339 23.4. Step 1: Create a New Project ........................................................................................................ 340 23.5. Step 2: Build the Model ................................................................................................................ 341 23.6. Step 3: Generate a Mesh .............................................................................................................. 344 23.7. Step 4: Physical and Numerical Settings ....................................................................................... 346 23.8. Step 5: Save the Model ................................................................................................................ 346 23.9. Step 6: Calculate a Solution .......................................................................................................... 346 23.10. Step 7: Examine the Results with CFD-Post ................................................................................. 347 23.11. Step 8: Thermo-Mechanical Structural Analysis ........................................................................... 349 23.12. Step 9: Summary ....................................................................................................................... 349 24. Postprocessing Using ANSYS CFD-Post ............................................................................................ 351 24.1. Introduction ............................................................................................................................... 351 24.2. Prerequisites ............................................................................................................................... 351 24.3. Problem Description ................................................................................................................... 352 24.4. Step 1: Create a New Project ........................................................................................................ 352 24.5. Step 2: Parametric Trials and Solver Settings ................................................................................. 354 24.6. Step 3: Calculate a Solution .......................................................................................................... 355 24.7. Step 4: Postprocessing Using ANSYS CFD-Post ............................................................................. 355 24.8. Step 5: Comparison Study ............................................................................................................ 378 24.9. Step 6: Summary ......................................................................................................................... 383 25. High Density Datacenter Cooling ..................................................................................................... 385 25.1. Introduction ............................................................................................................................... 385 25.2. Prerequisites ............................................................................................................................... 385 25.3. Problem Description ................................................................................................................... 385 25.4. Step 1: Create a New Project ........................................................................................................ 386 25.5. Step 2: Set Preferences ................................................................................................................ 387 25.6. Step 3: Build the Model ................................................................................................................ 388 25.7. Step 4: Generate a Mesh .............................................................................................................. 413 25.8. Step 5: Create Monitor Points ....................................................................................................... 413 25.9. Step 6: Physical and Numerical Settings ....................................................................................... 414 25.10. Step 7: Save the Model .............................................................................................................. 415 25.11. Step 8: Calculate a Solution ........................................................................................................ 415 25.12. Step 9: Examine the Results ....................................................................................................... 417 25.13. Step 10: Additional Exercise: Visualize and analyze the results in ANSYS CFD-Post ........................ 424 25.14. Step 11: Summary ..................................................................................................................... 424 26. Design Modeler - Electronics ............................................................................................................ 425 26.1. Introduction ............................................................................................................................... 425 26.2. Prerequisites ............................................................................................................................... 425 26.3. Problem Description ................................................................................................................... 425 26.4. Step 1: Create a New Project ........................................................................................................ 425 26.5. Step 2: Build the Model ................................................................................................................ 426 26.6. Step 3: Add Shortcuts to the Toolbar ............................................................................................ 427 26.7. Step 4: Edit the Model for ANSYS Icepak ....................................................................................... 428 26.8. Step 5: Opening the Model in ANSYS Icepak ................................................................................. 445 26.9. Step 6: Summary ......................................................................................................................... 447 Index ........................................................................................................................................................ 449
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Chapter 1: Using This Manual A mini flow chart is used to indicate the menu selections that lead you to a specific panel. For example, Model Generate mesh indicates that the Generate mesh option can be selected from the Model menu at the top of the ANSYS Icepak main window. The arrow points from a specific menu toward the item you should select from that menu. A mini flow chart is also used to indicate the list tree selections that lead you to a specific panel or operation. For example, Problem setup Basic parameters
indicates that the Basic parameters item can be selected from the Problem setup node in the Model manager window Pictures of toolbar buttons are also used to indicate the button that will lead you to a specific panel. indicates that you will need to click on this button (in this case, to open the Walls For example, panel) in the toolbar.
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2.2. Prerequisites
This tutorial assumes that you have little to no experience with ANSYS Icepak and so each step will be explicitly described.
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2.
Click New in the Welcome to Icepak panel to start a new ANSYS Icepak project. The New project panel appears.
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3.
Specify a name for your project and click Create. ANSYS Icepak creates a default cabinet with the dimensions 1 m 1 m 1 m, and displays the cabinet in the graphics window.
Note
You can rotate the cabinet around a central point using the left mouse button, or you can translate it to any point on the screen using the middle mouse button. You can zoom into and out from the cabinet using the right mouse button. To restore the cabinet to its default orientation, select Home position in the Orient menu.
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Extra
You can also open the Cabinet panel by selecting the Cabinet item in the Model manager window and then clicking the Edit object button ( ) in the Object modification toolbar. Resizing of the cabinet object can also be done in the geometry window in the lower right hand corner of the GUI. a. b. In the Cabinet panel, click the Geometry tab. Under Location, enter the following coordinates: xS yS zS 0 0 0 xE yE zE 0.075 0.25 0.356
c. d.
Click Done to resize the cabinet and close the panel. In the Orient menu, select Scale to fit to scale the view of the cabinet to fit the graphics window.
Extra
You can also scale the view by clicking the Scale to fit button ( ).
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Extra
After selecting the object to be edited in the model tree, there are several ways you can open the Edit panel: Double-click on the object in the model tree, or 2. Type Ctrl+e, or Right-click the object in the model tree and scroll to Edit object, or Click the Edit button in the object geometry window, or Click the Edit icon ( ) in the model toolbar.
Create the backing plate. The backing plate is 0.006 m thick and divides the cabinet into two regions: the device side (where the high-power devices are contained in a housing) and the fin side (where the fins dissipate heat generated by the devices). The backing plate is represented in the model by a solid prism block.
Extra
Blocks allow six-sided control for meshing and thermal specifications, whereas plates allow for only two-sided control. a. Click the Create blocks button ( ) to create a new block.
ANSYS Icepak creates a new solid prism block in the center of the cabinet. You need to change the size of the block. b. c. d. Click the Edit object button ( Click the Geometry tab. Enter the following coordinates for the block: xS yS zS 0 0 0 xE yE zE 0.006 0.25 0.356 ) to open the Blocks panel.
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e. 3.
Create the free opening on the fin side of the backing plate. a. Click the Create openings button ( ) to create a new opening.
ANSYS Icepak creates a free rectangular opening lying in the x-y plane in the center of the cabinet. You need to change the size of the opening. b. c. d. Click the Edit object button ( Click the Geometry tab. Enter the following coordinates for the opening: xS yS zS 0.006 0 0.356 xE yE zE 0.075 0.25 ) to open the Openings panel.
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e. 4.
Create the first fan. Each fan is physically identical to the others, except with respect to its location on the cabinet wall. To create the set of three fans, you will build a single fan as a template, and then create two copies, each with a specified offset in the y direction. a. Click the Create fans button ( ) to create a new fan.
ANSYS Icepak creates a free circular fan lying in the x - y plane in the center of the cabinet. You need to change the size of the fan and specify its mass flow rate. b. c. d. Click the Edit object ( Click the Geometry tab. Enter the following coordinates for the fan: xC yC zC e. 0.04 0.0475 0 ) to open the Fans panel.
Enter 0.03 for the external radius (Radius), and 0.01 for the internal radius (Int Radius).
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f. g. h.
Click the Properties tab. Keep the default Fan type of intake. Under the Fan flow tab, select Fixed and Volumetric. Enter a volume flow rate of 18 cfm.
Note
Make sure to update the units to cfm by clicking on the triangle button and selecting cfm from the drop-down list.
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i. 5. a. b. c. d.
Click Done to modify the fan and close the panel. In the graphics display window, select fan.1 using the Shift key and right mouse button. In the object context menu, select Copy and the Copy fan fan.1 panel opens. Enter 2 as the Number of copies. Enable the Translate option and specify a Y offset of 0.0775 m.
Copy the first fan (fan.1) to create the second and third fans (fan.1.1 and fan.1.2).
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e.
Click Apply. ANSYS Icepak makes two copies of the original fan, each offset by 0.0775 m in the y direction from the previous one.
6.
Create the first high-power device. Like the fans, each device is physically identical to the others, except with respect to its location in the cabinet. To create the set of five devices, you will build a single rectangular planar source as a template, and then create four copies, each with a specified offset in the y direction. a. Click the Create sources button ( ) to create a source.
ANSYS Icepak creates a free rectangular source in the center of the cabinet. You need to change the geometry and size of the source and specify its heat source parameters.
Note
For planar objects, select the desired plane first, then enter the coordinates.
b. c. d. e. f.
Keep the default selection of Rectangular. In the Plane drop-down list, select Y-Z. Enter the following coordinates for the source: xS yS 0 0.0315 xE yE 0.0385
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g. h.
Click the Properties tab. Under Thermal specification, set the Total power to 33 W.
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i. 7.
Copy the first device (source.1) to create the other four devices (source.1.1, source.1.2, source.1.3, and source.1.4). a. b. c. In the Model manager window, select the source.1 item under the Model node. Click the Copy object button ( ).
Follow the same instructions that you used above to copy the fans, using a Y offset of 0.045 m to create 4 copies.
8.
Create the first fin. Like the fans and devices, each fin is physically identical to the others, except with respect to its location in the cabinet. To create the array of ten fins, you will build a single rectangular plate as a template, and then create nine copies, each with a specified offset in the y direction. a. Click the Create plates button ( ) to create a plate.
ANSYS Icepak creates a free rectangular plate in the x-y plane in the center of the cabinet. You need to change the orientation and size of the plate and specify its thermal parameters. b. c. d. e. Click the Edit object button ( Click the Geometry tab. In the Plane drop-down list, select X-Z. Enter the following coordinates for the plate: ) to open the Plates panel.
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f. g. h. i.
Click the Properties tab. Under Thermal model, select Conducting thick from the drop-down menu. Set the Thickness to 0.0025 m. Keep default as the Solid material.
Note
Since the default solid material is extruded aluminum, you need not specify the material explicitly here.
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j. 9. a. b. c.
Click Done to modify the plate and close the panel. In the Model manager window, select the plate.1 item under the Model node. Click the Copy object button ( ).
Copy the first fin (plate.1) to create the other nine fins (plate.1.1, plate.1.2, ..., plate.1.9).
Follow the same instructions that you used above to copy the fans, using a Y offset of 0.025 m to create 9 copies.
The completed model will look like Figure 2.2 (p. 17), which is shown in the Isometric view (available in the Orient menu or by clicking the Isometric view button ( )).
Note
You can remove the object names by clicking the Display object names button ( ).
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10. Check the model to be sure that there are no problems (e.g., objects that are too close together to allow for proper mesh generation). Model Check model
Note
You can also click the Check model button ( ) to check the model.
Note
ANSYS Icepak should report in the Message window that 0 problems were found. 11. Check the definition of the modeling objects to ensure that you specified them properly. View Summary (HTML) The HTML version of the summary displays in your web browser. The summary displays a list of all the objects in the model and all the parameters that have been set for each object. You can view the detailed version of the summary by clicking the appropriate object names or property specifications. If you notice any incorrect specifications, you can return to the appropriate modeling object panel and change the settings in the same way that you originally entered them.
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Extra
For more information on how to refine a mesh locally, refer to Refining the Mesh Locally in the Icepak User's Guide. Model Generate mesh
Extra
You can also generate a mesh by clicking the Generate mesh button ( Mesh control panel. 1. Generate a coarse (minimum-count) mesh. a. In the Mesh control panel, select Coarse in the Mesh parameters drop-down list. ANSYS Icepak updates the panel with the default meshing parameters for a coarse (minimumcount) mesh, shown in the panel below. b. c. d. Set the Mesh units and all the Minimum gap units to mm. Set the Minimum gap to 1 mm for X, Y, and Z. Set the Max X size to 3.5, the Max Y size to 12.5, and the Max Z size to 17.5. ), which opens the
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e.
Note
If the Allow minimum gap changes option is unchecked under the Misc tab, ANSYS Icepak will inform you that your minimum object separation is more than 10% of the smallest size object in the model . You can stop the meshing process, ignore the warning, or allow ANSYS Icepak to correct the values. f. If this warning appears, click Change value and mesh in the Minimum separation in x and Minimum separation in y panels to accept the recommended changes to your model and continue generating the mesh. Click the Display tab.
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2.
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Chapter 2: Finned Heat Sink b. c. d. Turn on the Cut plane option. In the Set position drop-down list, select X plane through center. Turn on the Display mesh option. The mesh display plane is perpendicular to the fins, and aligned with the devices, as shown in Figure 2.3 (p. 21).
Note
The number of elements may vary slightly on different machines.
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e.
Use the slider bar to move the plane cut through the model. See Figure 2.4 (p. 22) to examine a close-up view of the coarse mesh.
Note
You can change the mesh color using the Surface mesh color and the Plane mesh color options. The mesh elements near the fins are too large to sufficiently resolve the problem physics. In the next step, you will generate a finer mesh. 3. Generate a finer mesh. a. b. Click the Settings tab. Under Global, select Normal in the Mesh parameters drop-down list. ANSYS Icepak updates the panel with the default meshing parameters and Minimum gap values for a normal" (i.e., finer than coarse) mesh. 4. 5. Click the Generate button in the Mesh control panel to generate the finer mesh. Examine the new mesh. The graphics display updates automatically to show the new mesh. Click the Display tab and use slider bar to advance the plane cut and view the mesh throughout the model.
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6.
Turn off the mesh display. a. b. c. Click the Display tab in the Mesh control panel. Deselect the Display mesh option. Click Close to close the Mesh control panel.
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Note
After deselecting the Display mesh option and closing the Mesh control panel, you can display the mesh on selected objects by using the context menu in the graphics display window. To display the context menu, hold down the Shift key and press the right mouse button anywhere in the graphics window, but not on an object. Select Display mesh and select the object you want it displayed on.
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a. b.
Click the Reset button. Reset calculates the Reynolds and Peclet numbers. Check the values printed to the Message window. The Reynolds and Peclet numbers are approximately 13,000 and 9,000, respectively, so the flow is turbulent. ANSYS Icepak will recommend setting the flow regime to turbulent.
Note
These values are only estimates, based on the current model setup. Actual values may vary, and may need to be verified, depending on your design. c. 2. Click Accept to save the solver settings.
In the Basic parameters panel, select Turbulent as the Flow regime. Keep the default Zero equation turbulence model. Turn radiation off by clicking Off under Radiation.
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b.
Note
Alternatively, you can click the button in the File commands toolbar.
Note
You can click the Run solution button ( ) in the Model and solve toolbar.
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2. 3.
Keep the default settings in the Solve panel. Click Start solution to start the solver.
Note
There are no universal metrics for judging convergence, a good indicator is when the solution no longer changes with more iterations and when the residuals have decreased to a certain degree. The default criterion is that each residual will be reduced to a value of less than except the energy residual, for which the default criterion is . It is a good idea to judge convergence not only by examining residuals levels, but also by monitoring relevant integrated quantities. ANSYS Icepak begins to calculate a solution for the model, and a separate window opens where the solver prints the numerical values of the residuals. ANSYS Icepak also opens the Solution residuals graphics display and control window, where it displays the convergence history for the calculation. Upon completion of the calculation, your residual plot will look something like Figure 2.6 (p. 27). You can zoom in the residual plot by using the left mouse.
Note
The actual values of the residuals may differ slightly on different machines, so your plot may not look exactly the same as Figure 2.6 (p. 27).
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4.
The following steps illustrate how to generate and display each view.
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Note
The objective of this exercise is to determine whether the air flow and heat transfer associated with the heat sink (fans and fins) are sufficient to maintain device temperatures below 65C. You can accomplish this by creating different plane cuts and monitoring the velocity vector and temperature on it. Plane-cut views allow you to observe the variation in a solution variable across the surface of a plane. You will use the Plane cut panel to view the direction and magnitude of velocity across a horizontal plane. 1. To open the Plane cut panel, select Plane cut in the Post menu.
Extra
You can also open the Plane cut panel by clicking the Plane cut button ( 2. Display velocity vectors on a plane cut on the fin side of the enclosure. Post Plane cut a. b. In the Name field, enter the name cut-velocity. In the Set position drop-down list, select X plane through center. ).
Tip
Click the triangle button located next to the Set position text field to open the drop-down list. c. Turn on the Show vectors option.
d. e.
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Step 7: Examine the Results This orients the model as shown in Figure 2.7 (p. 29). You can see that the maximum velocity occurs at the fan blades. The lowest velocity occurs between the top fin and the adjacent cabinet wall, and between the bottom fin and the adjacent cabinet wall.
Extra
You can also select the positive orientation by clicking the Orient positive X button ( ).
f.
In the Plane cut panel, turn off the Active option. This temporarily removes the velocity vector display from the graphics window, so that you can more easily view the next postprocessing object.
Note
You can later open the Inactive folder in the model tree and locate cut_velocity. cut_velocity can be either deleted or reactivated by dragging it to Trash or to the Post-processing folder, as well as with the right-click dialog. 3. Display contours of temperature on the fin side of the enclosure. a. b. c. d. Click New in the Plane cut panel. In the Name field, enter the name cut-temperature. In the Set position drop-down list, select X plane through center. Turn on the Show contours option and click Parameters. The Plane cut contours panel opens.
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Chapter 2: Finned Heat Sink e. f. g. h. Keep the default selection of Temperature. For Shading options, keep the default selection of Banded. For Color levels, select Calculated and then select This object from the drop-down list. Click Apply. ANSYS Icepak computes the color range for the display based on the range of temperatures on this plane cut.
i.
Click Done to save the new settings, close the panel, and update the graphics display. The graphics display updates to show the temperature contour plot. The actual values of temperature may slightly differ on different systems. You can use the scroll bar to change the x-location of the plane cut. In addition, the plane cut can be dragged through the model when you press the Shift key and hold down the middle mouse button on the plane. Ensure you click the edge of the plane cut so as to not move any objects. Figure 2.8 (p. 31) shows that heat conducts through the fins from the sources in both directions.
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j. 4. a. b. c. d.
In the Plane cut panel, turn off the Active option. Click New in the Plane cut panel. In the Name field, enter the name cut-prvelocity. In the Set position drop-down list, select X plane through center. Specify the display of velocity vectors. i. Turn on the Show vectors option and click Parameters. The Plane cut vectors panel opens. ii. iii. iv. Select Fixed from the Color by drop-down list. Click on the square next to Fixed color and select black from the color palette. Click Done to close the panel. Turn on the Show contours option and click Parameters. The Plane cut contours panel opens. ii. iii. iv. v. In the Plane cut contours panel, select Pressure in the Contours of drop-down list. For Shading options, keep the default selection of Banded. For Color levels, select Calculated and then select This object from the drop-down list. Click Done to save the new settings, close the panel, and update the graphics display. The graphics display updates to show the pressure contour plot superimposed on the velocity vector plot.
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e.
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Chapter 2: Finned Heat Sink Figure 2.9 (p. 32) shows isolated regions of high pressure immediately downstream of the fans, including local maxima at the upstream tips of the fins.
Figure 2.9 Pressure Contours and Velocity Vectors on the Fin Side of the Enclosure
f. 5.
Display contours of temperature on all five high-power devices. An object-face view allows you to examine the distribution of a solution variable on one or more faces of an object in the model. To generate an object-face view, you must select the object and specify both the variable to be displayed (e.g., temperature) and the attributes of the view (e.g., shading type). You will use the Object face panel to create a solid-band object-face view of temperature on all five high-power devices and on the backing plate. a. To open the Object face panel, select Object face in the Post menu. Post Object face
Extra
You can also open the Object face panel by clicking the Object face button ( b. c. d. In the Name field, enter the name face-tempsource. In the Object drop-down list, click source.1, hold down the Shift key, and click source.1.4 to select all the sources, and click the Accept button. Turn on the Show contours option. ).
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e.
Click Parameters next to the Show contours option. The Object face contours panel opens.
f. g. h.
In the Object face contours panel, keep the default selection of Temperature in the Contours of drop-down list. For Shading options, keep the default selection of Banded. For Color levels, select Calculated and then select This object from the drop-down list.
i.
Click Done to save the new settings, close the panel, and update the graphics display. The graphics display updates to show the temperature contours on the sources.
j.
Use your right mouse button to zoom in and look more closely at each source. Figure 2.10 (p. 34) shows a view with the temperature contours on all five sources. The temperature distributions are similar for all sources: warm in the center and decreasing in tem-
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33
Chapter 2: Finned Heat Sink perature toward the edges of the source. Temperature distributions on the top and bottom sources are similar to each other, as are distributions on the two remaining sources.
Note
To view the temperature contours on an individual source, hold down the Shift key and drag a box around a source object using the left mouse button. The source object will show as highlighted in the Model manager window. Right click the source object to display the context menu and select Create>Object face(s)>Separate. The Object face panel is displayed for that particular object. Change the settings to match the ones used above for all source objects and click Create.
k. 6. a. b. c. d.
In the Object face panel, turn off the Active option. Click New in the Object face panel. In the Name field, enter the name face-tempblock. In the Object drop-down list, select block.1 and click Accept. Turn on the Show contours option and click Parameters. The Object face contours panel opens.
e. f. g. h.
In the Object face contours panel, keep the default selection of Temperature in the Contours of drop-down list. For Contour options, deselect Solid fill and select Line. For Level spacing, select Fixed and set the Number of contour lines to 200. For Color levels, select Calculated and then select This object from the drop down list.
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Step 8: Summary i. Click Done to save the new settings, close the panel, and update the graphics display. The graphics display updates to show the temperature contours on the block. Figure 2.11 (p. 35) shows that most of the heat is confined to the region near the sources. The maximum temperature occurs near the middle three sources.
j. 7. a. b.
Click Done in the Object face panel to close the panel. Select Save post objects to file in the Post menu. Click on Save in the File selection window that opens. Upon saving the project, all objects created during post-processing are saved within a post_objects file for future retrieval.
Note
ANSYS Icepak does not automatically save the post-processing objects created in the current session. When you exit ANSYS Icepak, they are deleted unless they are saved using the above steps.
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Note
When you are finished examining the results, you can end the ANSYS Icepak session by clicking Quit in the File menu. File Quit
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Chapter 3: RF Amplifier
3.1. Introduction
This tutorial demonstrates how to model an RF Amplifier using ANSYS Icepak. In this tutorial you will learn how to: Create a new project. Create openings, fans, sources, enclosure, PCB, heat sink and walls. Use non-conformal meshing. Include effects of gravity and turbulence in the simulation. Calculate a solution. Examine contours and vectors on object faces and on cross-sections of the model.
3.2. Prerequisites
This tutorial assumes that you have little experience with ANSYS Icepak, but that you are generally familiar with the interface. If you are not, please review Sample Session in the Icepak User's Guide.
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Chapter 3: RF Amplifier
2.
Click New in the Welcome to Icepak panel to start a new ANSYS Icepak project. The New project panel appears.
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3.
Specify the name amplifier for your project and click Create. ANSYS Icepak creates a default cabinet with the dimensions 1 m 1 m 1 m, and displays the cabinet in the graphics window.
Note
You can rotate the cabinet around a central point using the left mouse button, or you can translate it to any point on the screen using the middle mouse button. You can zoom into and out from the cabinet using the right mouse button. To restore the cabinet to its default orientation, select Home position in the Orient menu.
Select the cabinet in the Model tree and specify the following in the object geometry window:
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Chapter 3: RF Amplifier
Extra
After selecting the object to be edited in the model tree, there are several ways you can open the Edit panel: Double-click on the object in the model tree, or Type Ctrl+e, or Right-click the object in the model tree and scroll to Edit object, or Click the Edit button in the object geometry window, or Click the Edit object icon ( ) in the model toolbar
One side of this cabinet has an opening. Assign Properties on this boundary, in the Properties tab of the Cabinet object panel (Figure 3.3 (p. 41)): a. b. Change the Max y Wall type to be an Opening. Click Done to accept the inputs and close the panel.
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2.
Create the Y and Z faces of the amplifier housing as an enclosure using the enclosure object. Click on the Create enclosures icon ( and dimensions: ) in the model toolbar, then specify the following Name
In the Properties tab specify the followings: a. b. Change the Boundary type to Open for Min X and Max X. For others, retain the boundary type as Thin. Specify the Solid material as Polystyrene-rigid-R12.
Tip
You have to scroll down the list to find this material. c. Click Done.
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Chapter 3: RF Amplifier
3.
Create the Xmin face of the amplifier housing as a wall. The wall covers the Xmin side of the enclosure.
4.
In the object edit window, name the wall Xmin and change the plane to Y-Z.
Note
While we will use the align tools to place the wall at the desired locations, we could also specify the dimensions/locations of the wall in the Geometry tab and achieve the same result. However, the align tools are faster, and thus are the recommended method. To start the process, left-click Morph Edges icon ( by-step procedure described below: a. b. c. ) in the model toolbar. Now, follow the step-
Select the Zmax edge of the wall (Figure 3.5 (p. 43)) by left mouse clicking it in the graphical window. Notice that it turns red to indicate that it has been selected. Click the middle mouse button to accept this edge. Select the lower Zmax edge of the enclosure (Figure 3.5 (p. 43)) with the left mouse button. Notice that it turns yellow to indicate that it has been selected.
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d.
Click the middle mouse button to accept the transformation. The wall Xmin should have now been moved and resized. Now the wall should extend to the entire Xmin side of the enclosure.
To specify the remaining wall dimension, stay in the match edge mode and complete the following steps: a. Click the Zmin edge of the wall with the left mouse button. Be sure that it (and not the enclosure edge) is highlighted in red. By repeatedly clicking the left mouse button, ANSYS Icepak cycles through all possible edges. Click the middle mouse button to accept. Using the left mouse button, click the lower Zmin edge of the enclosure. Click the middle mouse button to accept. The wall should now form the Xmin face of the enclosure. Click the right mouse button to exit the Match edge mode.
b. c. d. e.
The resulting model is shown in Figure 3.6 (p. 44) with shading to highlight new definitions. Shading is available under the Info tab in most panels.
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Chapter 3: RF Amplifier
Double-click on the newly created wall object (Xmin) in the model tree to open the Walls panel. Now specify the following properties to the wall in the Properties tab. a. b. c. Specify a Wall thickness of 1 mm (0.001 m). Specify the Solid material as Polystyrene-rigid-R12 under Plastics. Specify the External conditions as Heat transfer coefficient and click the Edit button. The Wall external thermal conditions panel opens.
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Step 2: Build the Model i. Select Heat transfer coefficient in the External conditions drop-down list and press Edit. The Wall external thermal conditions panel opens. Set the Heat transfer coeff to 5 W/K-
Click Done to close the Wall external thermal conditions panel. Click Done to close Walls panel (Figure 3.7 (p. 45))
5.
Create the PCB. The PCB will cover the Xmax side of the enclosure. a. b. Click on the Create printed circuit boards icon ( double click on the PCB object in the Model tree. Specify the following in the geometry window: ) in the Model toolbar to create a PCB and
c.
Specify the Trace layer type as Detailed and input the parameters under Trace layer parameters (make sure that you enter both columns) in the Properties tab as shown in Figure 3.8 (p. 46). There are four internal layers. Please notice that the Effective conductivity in plane and normal directions are updated when you click on the Update button (Figure 3.8 (p. 46)).
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Chapter 3: RF Amplifier
d. 6.
Create the devices as 2D sources. There are 12 devices on the bottom side of the PCB. Theses devices are created as 2D sources. The following steps show you how to create one and then use the copy utility to create the remaining 11 sources. a. b. Click on the Create sources icon ( ) in the model toolbar to create a source and double click on the source object in the model tree. Specify the following name, dimensions, and properties to the source.
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c.
In the Properties tab, specify the Total power as 7 W (Figure 3.9 (p. 47)) and click Done.
d.
Create the other devices (sources) object by creating two copies of the device and translating it to z= 0.055 m. Please follow the steps below for copying the source object. i. ii. iii. iv. v. Right mouse click on the source object and choose the Copy option. Specify the Number of copies as 2. Turn on the Translate option. Specify the Z offset to 0.055 m. Click Apply to copy the object.
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Chapter 3: RF Amplifier
e.
Similarly, create the other devices (sources) object by copying the sources created in the previous steps. i. ii. iii. iv. v. Left mouse click and select device, then while holding down the Ctrl key, select device.1, and device.2. Right mouse click and choose the Copy option. Specify the Number of copies as 3. Turn on the Translate option. Specify the Y offset to 0.064 m. Click Apply to copy the object.
Note
Following these two copy actions, you should now have 12 sources (Figure 3.11 (p. 49)) in a four rows by three columns pattern.
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7.
Create the heat sink. The extruded fin heat sink with the flow in the y direction will be created to remove the heat from the PCB. a. Click on the Create heat sinks icon ( ) in the Model toolbar to create a heat sink and double click on the heat sink object in the model tree. Specify the following dimensions in the geometry window.
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Chapter 3: RF Amplifier
b. c.
In the heat sink object panel, select the Geometry tab, and specify a Base height of 0.004 m and an Overall height of 0.04 m. Specify the properties of the heat sink as shown in Figure 3.12 (p. 50) below. Note that we are not changing parameters in the Flow/thermal data, Pressure loss, or Interface tabs.
d. 8.
Create the fan. For this model, we will make use of ANSYS Icepak's fan library and search tool. a. b. Select the Library tab in the model manager window(Figure 3.13 (p. 51)). Right-click on Libraries in the model tree and choose Search fans. The Search fan library dialog appears. i. ii. In the Physical tab, deactivate the Min fan size and enter 80 mm for the Max fan size. Select the Thermal/flow tab, enable the Min flow rate option and specify a Min flow rate of 80 cfm.
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Note
The minimum flow rate used in the search criteria implies the minimum free flow of the fans. iii. Click on the Search button.
Note
ANSYS Icepak lists all the fans in its libraries that satisfy these conditions. c. d. Select the fan called delta.FFB0812_24EHE in the Name column by clicking on it with the left mouse button. Click Create to load the fan into the model.
e.
Now, we need to specify the location of the fan created in the previous steps. Resize the fan geometry based on the Figure 3.14 (p. 52) (note X-Z plane).
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Chapter 3: RF Amplifier
The final geometry should look like Figure 3.15 (p. 53).
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f.
Check the definition of the modeling objects to ensure that you specified them properly. View Summary (HTML)
Note
The HTML version of the summary displays in your web browser. The summary displays a list of all the objects in the model and all the parameters that have been set for each object. You can view the detailed version of the summary by clicking the appropriate object names or property specifications. If you notice any incorrect specifications, you can return to the appropriate modeling object panel and change the settings in the same way that you originally entered them.
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Chapter 3: RF Amplifier 1. To create the amplifier assembly: a. b. Select the positive X view by either using the icon in the shortcut menu or simply press Shift+X and then Shift+S to fit to scale the view in the graphics window. While pressing Shift, drag a bounding box around the amplifier using the left mouse button. Release the mouse button and notice that all of the objects forming the amplifier and heat sink have been selected in the model tree. Right-click on the highlighted enclosure (Housing) in the model tree and select Create and then Assembly from the list. All of the selected objects have now been added to the assembly. In the Object geometry window, rename the assembly assembly.1" to amplifier and click Apply.
c. d. 2.
Create a new assembly for the fan object: a. b. c. Click on the Create assemblies icon ( ) in the model toolbar to create a new assembly.
In the Model tree, use the left mouse button to drag the fan, delta.FFB0812_24EHE, into the new assembly to add it to this assembly. In the Object geometry window, rename this assembly as fan and click Apply.
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Chapter 3: RF Amplifier 2. Toggle on Mesh separately and then specify the slack values indicated in the following table. Make sure you remember to add slack values to both assemblies.
3.
To create the mesh, go to Model Generate Mesh. The Mesh control panel (Figure 3.18 (p. 57)) appears. The Mesh control panel can also be opened by clicking on the Generate mesh icon ( the shortcut menu. ) in
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4.
As a first step, generate a coarse mesh by choosing Coarse in the Mesh parameters drop-down list in the Global tab, as shown in Figure 3.18 (p. 57). Click Generate to create a mesh.
Note
If you have unchecked Allow minimum gap changes in the Misc tab, the Minimum separation warning will appear. This warning message appears when the minimum gap specified is more than 10% of the smallest sized object in the model. Please select Change value and mesh if the warning message pops up. 5. 6. To view the mesh, display a plane-cut view through the center of the cabinet, perpendicular to the fins (y-z plane). To create a plane-cut, follow these steps: a. b. c. d. e. Click on the Display tab at the top of the Mesh control panel. Toggle on Display mesh and Cut plane. Under Plane location, set position to X plane through center in the drop-down list. Press Shift+X to orient to the positive X direction and view the newly created plane cut. Move the plane using the slider bar to see different views.
Make sure that the amplifier assembly is expanded and inspect the cells adjacent to the heat sink fins. Notice that the resolution is coarse (Figure 3.19 (p. 58)), with only a couple of cells between fins. As flow passes between the fins, boundary layers will grow and their degree of resolution
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Chapter 3: RF Amplifier will dictate the accuracy of the simulation. It is advisable to have at least three to four cells between fins to adequately resolve the growth of boundary layers. Better resolution is achieved by refining the mesh. 7. Choose Normal in the Mesh parameters drop-down list in the Settings tab. Click Generate and inspect the resulting mesh. Note that the number of cells between adjacent fins have increased (Figure 3.19 (p. 58)), providing better resolution of the boundary layers. You can display the mesh on selected objects or the cut plane by using the context menu in the graphics display window. To display the context menu, hold down the Shift key and press the right mouse button anywhere in the graphics display window. Select Display mesh or Display cut plane mesh in the context menu and the mesh will be displayed on selected objects or the cut plane will be displayed. It is also a good practice to select the Quality tab and review the Face Alignment, Quality, Volume, and Skewness. The histograms show the figure of merit (Face Alignment, Quality Ratio, Volume or Skewness) versus number of cells. By clicking on the bars that form the histogram, the particular cells with that value of quality are displayed in the graphics window.
8.
Once you have explored the mesh quality, click Close to dismiss the Mesh control dialog box.
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Step 5: Physical and Numerical Settings Solution settings a. b. Click the Reset button. Check the values printed to the Message window. The Reynolds and Peclet numbers are approximately 56282.6 and 39876.6 respectively, so the flow is turbulent. ANSYS Icepak recommends setting the flow regime to turbulent. Basic settings
Note
These values are only estimates, based on the current model setup. Actual values may vary, and may need to be verified, depending on your design. c. 2. Click Accept to save the solver settings.
In the Basic parameters panel, select Turbulent as the Flow regime and keep the default Zero equation turbulence model. Turn on the Gravity vector option and make sure that gravity in the y-direction is -9.8 m/
b.
Note
Specifying gravity is important for the natural convection inside the RF amplifier. c. d. Turn off radiation. Click Accept to save the new setting.
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Chapter 3: RF Amplifier
3. 4.
Return to the Basic settings panel, specify the number of iterations as 300, click Reset and then Accept again. Set up the temperature limits for all the sources. Model Power and temperature limits a. b. c. Enter a new value of 60C for Default temperature limit. Click on All to default. Click Apply and then click Accept to close the panel.
Note
The default temperature limit is used during postprocessing to identify components that exceed their limits or components that are close to this limit. This value is not used to solve the problem.
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Note
You can click the save button ( ) in the File commands toolbar.
Note
It is good practice to monitor the solution progress for certain objects. Dragging the object in the model tree and placing it in the Points folder can accomplish this. a. b. c. d. Drag device.2 and cabinet_default_side_maxY into the Points folder. Right mouse click on the cabinet_default_side_maxY in the Points folder. Select Edit and deselect temperature and activate Velocity (Figure 3.21 (p. 61)). Click Accept to accept the modifications and to dismiss the per-object's Modify point panel.
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Note
Alternatively, you can click on the Run solution icon ( toolbar to display the Run solution panel. a. b. ) in the model and solve
Enable Write overview of results when finished in the Results tab. Click on the Start solution button to start the solver. While iterating the solution, windows will appear showing convergence history, Figure 3.22 (p. 62) and Figure 3.23 (p. 63).
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Note
Ensure that the amplifier and fan assemblies are expanded, so that the fins are visible.
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Chapter 3: RF Amplifier a. b. c. d. Press Shift+Z to orient the view in the positive Z direction. To create an object face, click the Object face icon ( ) in the shortcut toolbar.
In the Object drop down list, specify heatsink.1 as the object and click Accept. Select Show contours and click the Parameters button (adjacent to show contours) to access the Object face contours edit dialog box. i. ii. Select This object in the drop-box adjacent to Calculated to use the object-based range. Click Done to close the Object face contours panel.
e.
Note
You can also create contours on heatsink.1 by selecting this object in the Model manager window and click the right mouse button to display the context menu. Select Create>Object face(s)>Separate and the Object face panel will appear. The Object face panel is displayed for that particular object.
Note
Using the mouse, rotate the heat sink to examine the surface temperature distribution. Notice that the location of the devices is clearly discernible on the bottom of the heat sink. Also note that the devices get progressively hotter in the flow direction (Figure 3.25 (p. 65)).
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Note
Notice that face.1 has now appeared in the model tree in the Post processing folder. Right mouse click on face.1 and note that you can deactivate, edit, and delete it. You can move face.1 into the Inactive folder to deactivate it. Face.1 can be either deleted or reactivated by dragging it to Trash or to the Postprocessing folder, as well as with the right mouse click dialog. 3. Create plane cuts. a. b. To create a plane cut, click the Plane cut icon ( ) in the shortcut toolbar.
Select the Set position as Point and normal and select Show vectors, as shown in the panel below. Enter PX, PY, and PZ, as well as NX, NY, and NZ according to Figure 3.26 (p. 66).
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c. d. e.
Click the Parameters button adjacent to Show vectors. Select Uniform in Display options group box and specify value as 5000. The Uniform option for the velocity will put the vectors uniformly in the 5000 data points. Select This object in the drop-box adjacent to Calculated and click Done to close the panel.
The vector plots are shown in the graphics window (Figure 3.27 (p. 67)).
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Note
Examining the vector plot, we can see that the flow pattern is symmetric, with two large recirculating zones adjacent to the fan. Zoom into the region directly in front of the fan and notice that two smaller recirculating zones exist in front of the hub. These local effects can be important when objects are close to the hub region.
Note
You can move a plane cut through a model by pressing the Shift key, holding down the middle mouse button on the edge of a vector and dragging the plane cut through the model in the graphics display window. 4. Create isosurfaces. a. Click the Isosurface icon ( ) in the shortcut toolbar. 67
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Chapter 3: RF Amplifier b. Specify Temperature as the Variable, input a Value of 55C, and select Show contours and click Parameters. In the Isosurface contours panel, select Smooth for Shading options and This object in the drop-box adjacent to Calculated. Click Done. Click Update in the Isosurface panel and notice that an isosurface has been placed around all of the sources, indicating that they have temperatures in excess of 55C (Figure 3.28 (p. 68)).
c.
d. e.
Now, change the Variable to Speed and input a Value of 4. Click Update. Notice that the regions with velocities in excess of 4 m/s are now displayed (Figure 3.29 (p. 69)). Once you have examined the isosurface, delete or deactivate it using one of the previously described methods.
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5.
Create variation plots. a. Click the Variation plot icon ( ) in the shortcut toolbar.
Note
Before creating the variation plots, please ensure that the amplifier assembly is expanded, so that the fins are visible. Next, press Shift+Z to orient the view in the positive Z direction. b. Within the variation plot dialog box, complete the following: i. ii. iii. iv. c. Specify the Variable as UY. Click the From screen button. Click the left mouse button on the center on the heat sink fins. Click Create.
An xy-plot of UY velocity versus z-coordinate should now be visible. Toggle on the Symbols button and notice that the velocity profile across the solution domain is now represented with dots at the postprocessing locations. Notice that ANSYS Icepak has created a line that is colored locally according to the UY velocity magnitude. Save the xy-plot. i. ii. iii. Click the Save button at the bottom of the Variation of UY plot window. Enter a file name in the resulting Save curve dialog box. Click Save to save the file in the model folder.
d.
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Chapter 3: RF Amplifier
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4.2. Prerequisites
This tutorial assumes that you have little experience with ANSYS Icepak, but that you are generally familiar with the interface. If you are not, please review Sample Session in the Icepak User's Guide and the tutorial "Finned Heat Sink" of this guide as some of the steps that were discussed in these tutorials will not be repeated here.
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Extra
The previous tutorial showed you how to enter these values in the Cabinet panel. 2. Create the Fan. Click on the Create fans icon ( ) in the object toolbar next to the model tree to create a 2D intake circular fan on one side of the cabinet. Change the plane to yz and enter the location values shown in the geometry window below:
Defining a parameter for multiple trials. One of the objectives of this exercise is to parameterize the location of the fan. To create a parametric variable in ANSYS Icepak, input a $ sign followed by the variable name. Thus, to create the parametric variable zc, type $zc in the zC box in addition to the other location values, and click Apply. When ANSYS Icepak asks you for an initial value of zc", enter an initial value of 0.1, and click Done.
We will now set the physical properties that will define the fan behavior: a. b. c. Edit the fan object and go to Properties tab. In the Properties tab, retain the selection of Intake for Fan type and select Non-linear in the Fan flow tab. Enter the characteristic curve by clicking on the Edit button and selecting Text Editor in the dropdown list in the Non-linear curve group box.
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d.
First change the units of the volume flow rate and pressure according to the units in Table 4.1: Values for the Curve Specification Panel (p. 74) and enter the values in pairs with a space between them in the Curve specification panel.
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g. h. i.
Click Done to close the Fan curve panel. In the Properties tab, give the fan an RPM of 4000 in the Swirl tab, located next to the Fan flow tab. In the Properties tab, give the fan an Operating RPM of 2000 in the Options tab, located next to the Swirl tab.
Note
The fan curve defined originally for RPM=4000 will be automatically scaled according to the fan laws for the new operating RPM=2000. The swirl RPM(4000) can also be used to compute the swirl factor. j. Click Update and Done to close the fan window.
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Extra
The shading of the fan object can be changed by changing the Shading option under the Info tab to change the shading of just that object, or by leaving it as default and changing the default shading option by going to View Default shading to change the shading of all objects that have default shading selected. 3. Set up a Grille. a. Click on the Create grille icon ( ) for creating a new grille, set its plane to yz. Then, using the morph faces option move the grille to the max-X face of the cabinet. Step by step instructions on how to use the morph faces option is presented in the graphics display window after clicking the icon ( ) or you can also resize the grille as shown in the panel:
b.
We will now define properties for the grill by clicking the Properties tab.
Note
This is a 50% open perforated thin grille. i. ii. Under velocity loss coefficient, retain the default selection of Automatic. Specify a Free area ratio of 0.5.
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Step 2: Build the Model iii. iv. Retain Perforated thin vent for the Resistance type. Click Update and then Done to close the panel.
For more details on loss coefficient data, please refer to Handbook of Hydraulic Resistance, by I. E. Idelchick. The model looks as shown in Figure 4.6 (p. 77).
4.
Set up a wall.
Note
The model includes a 0.01 m thick PCB that touches and covers the entire min-Y floor of the cabinet. The PCB is exposed to the outside with a known heat flux of 20 W/m2. In order to take in consideration the heat flux, we will use a wall object to simulate the PCB. a. Click on the Create walls icon ( ) to create a new wall. We will define the geometry and physical parameters for the wall object: i. ii. iii. Make the plane xz. Use the morph faces icon ( ) from the model toolbar so that the wall object covers the entire min-Y floor of the cabinet. Edit the Wall object and go to Properties tab.
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Chapter 4: Use of Parameterization to Optimize Fan Location iv. v. vi. In the Material group box, set the Wall thickness to 0.01 m and the Solid material to FR4. In the Thermal specification group box, specify a Heat flux of 20 W/m2. Click Update and then Done to close the panel.
After creating the wall, the model looks as shown in Figure 4.7 (p. 78).
5.
Create blocks. In this step, we will create several types of blocks to represent different physics. Creation of Solid Blocks Now, we will create four blocks that dissipate 5 W each and have a contact resistance of 0.005 C/W on their bottom faces. a. Create a new block ( ) , and retain the type as solid and geometry as Prism. Enter the location values shown in the panel below:
b.
Edit the block and specify the following in the Properties tab:
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Step 2: Build the Model i. In the Surface specification group box, click on the Individual sides check box and click Edit (Figure 4.8 (p. 79)). A. B. C. D. E. Select MinY and toggle on Thermal properties and Resistance. Under Thermal condition, retain the selection of Fixed heat and Total power of 0 W. Select Thermal resistance from the drop-down menu next to Resistance. Set Thermal resistance to 0.005 C/W and click Accept. Click Accept to close the panel.
In the Thermal specification group box in the Properties tab, retain the selection of default for Solid Material (you can also select Al-Extruded which is the default). Set Total Power to 5 W. Click Update and Done to close the panel.
Extra
The previous tutorial showed you how to make a copy of an object.
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Creation of Network blocks Let us now create four IC chips in the form of network blocks. To create a network block, we will create a Block object and change the block type to Network in the Properties tab. Each network block will have junction-to-board, junction-to-case, and junction-to-sides thermal resistances. The values of these resistances are known a priori. a. Add a new block, and position it as shown in the panel below:
b.
Edit the block to change the properties of this block; Ensure that the Block type is set to Network. Toggle on Star Network. Enter the Network parameters as shown in Figure 4.10 (p. 81).
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c.
Now make three copies of this network block with an X offset of 0.08 m. This finishes the creation of the network blocks.
Note
Finally, to cut out a section of the cabinet from the computational domain, we can create a hollow block. This represents a region that does not affect heat transfer, but alters the flow patterns. a. b. c. d. e. f. Create a new Block; make sure it is a hollow. In the Geometry tab, create a new Local coord system. Select Create new from the Local coord system: drop-down list. Enter X offset = 0.1, Y offset = 0, Z offset = 0. Click Accept. This is just to demonstrate the use of local coordinate system. Further, size the block as follows:
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6.
Now we will create the detailed heat sink. The heat sink base acts as a heat spreader for all the chips. a. Click on the Create heat sinks icon ( in the following table: ) and edit it, entering its location and properties as shown
Click Update and Done. This completes the model building process. The complete model should look like that shown in Figure 4.11 (p. 83).
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Chapter 4: Use of Parameterization to Optimize Fan Location Min Y Min Z 0.005 m 0.005 m Max Y Max Z 0.005 m 0.005 m
Note
Note that for the Heatsink-packages-asy, we have set a bounding box that is 0.005 m bigger than the assembly at five sides except Max X where the slack is defined higher (0.015 m) to capture the wake region of the flow.
5.
Click Update and Done to complete the bounding box specifications for the assembly. Following the same procedure above, create one more assembly for the fan object (name it Fanasy). Use the following table to assign the Slack values for the Fan-asy assembly.
Extra
This warning appears because the Minimum gap (separation) which is like a tolerance setting for the mesher is larger than 10% of the smallest feature in the model. When there are objects smaller than the mesher tolerance, those objects will not be meshed correctly. To avoid this we use the change value and mesh option which modifies the minimum gap to 10% of the smallest object. This option is used for this particular tutorial and may not be applicable all the time. As separation setting is a useful tool designed to avoid unnecessary mesh due to inadvertent misalignments in the model (without modifying the geometry), we may use other options suitable to the model. 3. 4. 5. Click on Change value and mesh. Examine the mesh by taking plane cuts; examine Face alignment and Quality ratio. Go to the Mesh control panel, click on the Display and Quality tabs to examine the mesh.
Step 5: Setting up the Multiple Trials 1. Go to the Solve menu and select Define trials. a. b. c. The Parameters and optimization panel pops up. Toggle on Parametric trials in the Setup tab. Select the Design variables tab and next to Discrete values, type 0.165 following 0.1, separated by a space as shown in the Figure 4.12 (p. 85):
Figure 4.12 The Parameters and optimization Panel- Design variables tab
d.
Click Apply.
Note
After the first trial has been completed, ANSYS Icepak has the options of starting the following trial(s) from the default initial conditions specified in Problem setup panel, or from the solution(s) of the trial run(s) that have completed.
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Chapter 4: Use of Parameterization to Optimize Fan Location For this model, next go to the Trials tab and ensure the Restart ID is blank for the 2nd trial as shown in Figure 4.13 (p. 86). This instructs ANSYS Icepak to start the 2nd run from the default initial conditions. 2. Click on Reset button and select Values to use the base names for trial naming.
3.
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Solution settings
Basic settings
Enter 200 in the Number of iterations field in the Basic settings panel.
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Step 9: Calculate a Solution Icepak session. (If you start the calculation in the current ANSYS Icepak session, ANSYS Icepak will simply overwrite your job file when it saves the model.) File Save project Alternatively, click the save button ( ) in the file commands toolbar.
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Important
To view the 2nd parametric run, click on the Post menu and select Load solution ID. Select the solution that corresponds to the second parametric run, i.e., zc = 0.165. The graphics display window updates automatically. 2. Object face panel to display temperature contours on wall.1 and on all blocks
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3. 4.
Object face panel to display temperature contours on the faces of the PCB (wall.1) and on all blocks Surface probe panel to display the temperature values at a particular point
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Step 13: Additional Exercise to Model Higher Altitude Effect Examine the solution sets of both runs. You will find that, in the second run, the maximum temperature is lower than in the first run and that the network blocks are the hottest objects inside the cabinet. The second trial has the fan located at zC= 0.165 which is closer to the heat sink location. This increases the flow velocity over the heat sinks and thus increases the convective heat transfer coefficient, which leads to more heat transfer from the fins (blocks) and thus reduces the maximum temperature.
Examine these results. Go to the Report menu and then select Solution overview and click on View to display the desired overview report. 2. Summary Report You can also create a single summary report containing the results of all the trial runs completed. Go to the Solve menu and select Define report. In the Define summary report panel, under ID pattern, enter the default filter, "*", which picks all the available solution IDs. Press new and hold down Ctrl and select block.1, block.1.1., block.2, block.2.1, and block.3 from the drop-down menu under Objects, and then press Write. Verify that the second trial gives lower temperatures.
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Then, select Problem setup Basic Parameters and assign the new air material to the default fluid.
In addition, in the Fan flow section of the Fans Properties tab, all the defined fan curves need to be modified by multiplying the existing data with the ratio of densities (the density of air at 3000 m / the density of air at 0 m), which in this case is smaller than 1. Finally, the model is ready to be run to account for the effects of higher altitude.
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5.2. Prerequisites
This tutorial assumes that you have reviewed Sample Session in the Icepak User's Guide and Tutorials "Finned Heat Sink" and "RF Amplifier" of this guide.
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Chapter 5: Cold-Plate Model with Non-Conformal Meshing yS zS 0.0 m 0.0 m yE zE 0.3 m 0.2 m
Blocks Create a solid block, block.1, and a fluid block, block.2 with the following specifications. The table below also gives the geometrical region where block.2 is located to have the material properties of the fluid.
Note
Because Al-Extruded is set as the Default solid in the Defaults tab of the Basic parameters panel, you can then leave the material selection as default while creating the object instead of selecting the material each time when an object is being created. Next, we will create some cylindrical blocks. While editing cylindrical blocks, first select the block shape as cylinder, then select the desired plane and finally enter the dimensions.
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Step 2: Build the Model Object Geometry: Cylinder Plane: X-Z block.6 Geometry: Cylinder Plane: X-Z Because the fluid blocks, block.5 and block.6, are created after the solid blocks, they will have higher relative meshing priorities. 0.3 m 0.0 m 0.1 m 0.09 m 0.01 m 0.0 m Block type: Fluid Fluid Material: Water(@280K) xC yC zC Height Radius IRadius Specifications Fluid material: Water(@280K)
Note
An alternative way to build the cylinders would be to create the solid block, block.3, and then the fluid block, block.5, group these together, and then copy them with an offset of 0.2 in the x direction. Note that the naming of the cylinders will not be consistent with the tutorial. However, you could rename the objects to their corresponding names in the tutorial by right mouse clicking each copied object in the Model tree and selecting Rename. Plates
Note
Note: An alternative way to create plate.2 would be to copy plate.1 with a Z offset of 0.07m. Openings
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Chapter 5: Cold-Plate Model with Non-Conformal Meshing The openings at the liquid inflow and outflow regions of the cold-plate are
Note
You could also have made a copy of outlet opening (opening.1) with an X offset of 0.2 to create inlet opening (opening.2). The openings at the cabinet boundary for external air natural convection are
Note
Instead of creating the openings, opening.3 and opening.4 above, you could have edited the cabinet and changed the wall type on these two faces to openings. The final model should appear similar to the drawing shown in Figure 5.1 (p. 101).
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Note
Figure 5.1 (p. 101) has changed the opacity, shading and color of some objects to make the objects easier to see.
The bounding box of the assembly is larger than the original assembly by 0.01 m on five sides. The slack value for the min Y side of the assembly is set to be 0 m, since the min Y side of the assembly is at the bottom surface of the cabinet. Click Update and Done to complete editing the separately meshed assembly.
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Click Generate to mesh the model. Visualize the mesh at plane cuts and surface displays from the Display tab. 102
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Note
For steady state natural convection cases, setting a small initial velocity opposite to the gravity vector direction is advised as this assists with the initial convergence of the model. For cases where there is no forced convection, clicking on Reset in the Solution settings Basic settings menu automatically sets a small initial velocity in the direction opposite to the gravity vector. This may not be necessary in this model though, because the flow will be forced through the cold plate. We will have mixed convection (forced + natural) heat transfer mode.
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Select the Basic settings panel from the Solution settings branch of the tree and set the Number of iterations to 300. Go to Advanced settings and make sure Under-relaxation factors for Pressure, Momentum, and Temperature are 0.3, 0.7, and 1.0, respectively. Change the Stabilization under Joule heating potential to BCGSTAB, and select Double for the Precision drop-down list. The recommended basic settings and advanced solver setup for this model are shown in Figure 5.3 (p. 104). Add three monitor points to the Points folder, one to monitor the velocity at the center of the opening.1 (outlet opening), and two to monitor the temperature at the center of block.2 and plate.2, respectively. The easiest way to create them is to select the objects from the Model tree and then drag them to the Points folder of the tree. ANSYS Icepak will then automatically monitor values at the centers of these objects. The default setting is to monitor Temperature. To change this, double click on the object under the Points folder, and choose which variables to monitor at that location.
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Object: all blocks (select the blocks using Object-face view of temperature on all the blocks. the Ctrl key or the Shift key and the left What is the maximum temperature? mouse button) Show contours/Parameters Contours of: Temperature Contours options: Solid fill and Smooth Color levels: Calculated/Global limits
cut.1
Set position: Z plane through center Show vectors/ Parameters Color by: Velocity Magnitude Color levels: Calculated/Global limits
Observation: Water is circulating through the internal channel, providing most of the cooling for the model. On the outside, air flows over the system by natural convection. Observe the flow pattern from inlet opening to outlet opening passing through the cold plate. Animate the particle traces.
face.2
Objects: opening.1 (outlet) and opening.2 (inlet) Show particle traces/ Parameters Variable: Speed Display options: Uniform: 30 Particle options: Keep all the defaults Style: Dye trace (Width = 1) and Particles (Radius = 2) Color levels: Calculated/ This Object
cut.2
Observe the flow pattern in (+) X direction. Animate the particle traces.
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Chapter 5: Cold-Plate Model with Non-Conformal Meshing Variable: Speed Display options: Uniform: 30 Particle options: Keep all the defaults Style: Dye trace (Width = 1) and Particles (Radius = 2) Color levels: Calculated/ This Object cut.3 Set position: Y plane through center Show contours of Temperature. Due to the nature of the problem, the temperature distribution should be symmetric around the central xy plane. Please verify this in the solution.
You can save the postprocessing objects that you just created by clicking Save post objects to file option in the Post menu. ANSYS Icepak will save these objects under the file named post_objects in the Icepak project folder. If you do not save them at this stage, they will not be automatically saved for future retrieval when you end the current ANSYS Icepak session.
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6.2. Prerequisites
This tutorial assumes that you have little experience with ANSYS Icepak, but that you are generally familiar with the interface. If you are not, please review Sample Session in the Icepak User's Guide and the tutorial "Finned Heat Sink" of this guide. Some steps in the setup and solution procedure will not be shown explicitly.
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2.
Note
ANSYS Icepak can be started in ANSYS Workbench using the import .tzr feature or it can be opened as a stand-alone product.
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Step 2: Build the Model 3. 4. 5. Click Unpack in the Welcome to Icepak panel. In the File selection panel, select the packed project file heat-pipe-nested-NC.tzr and click Open. In the Location for the unpacked project file selection dialog, select a directory where you would like to place the packed project file, enter a project name in the New project text field then click Unpack.
Click on the material name with the right mouse button and select Edit or double click the material name to open the Edit panel. Go to the Properties tab and make sure to toggle on Material type to be Solid and set the Conductivity type to be Orthotropic from the drop-down list. Deselect the Edit check box next to conductivity and create the following materials with orthotropic conductivity properties using the template in Figure 6.2 (p. 110).
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The above materials have the so-called orthotropic conductivity, which is not uniform in all three directions. The effective conductivity in each direction is equal to the Nominal conductivity multiplied by the orthotropic multiplier in that direction. 2. After creating these heat pipe materials, we build the heat pipe made of cylindrical blocks and square joints. Create five block objects. Use the values in the following table (be sure to note the geometry)
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Step 2: Build the Model Object pipe2 Geometry Shape: Cylinder Plane: Y-Z pipe3 Shape: Cylinder Plane: X-Z Object Joint1 Geometry Shape: Prism xS 0.295 m yS 0.095 m zS 0.085 m xE 0.325 m yE 0.125 m zE 0.115 m 0.31 m 0.125 m 0.1 m 0.225 m 0.01 m 0.0 m xC 0.325 m yC 0.365 m zC 0.1 m Height 0.267 m Radius 0.01 m IRadius 0.0 m Specifications Type: Solid
Joint2
Shape: Prism
0.295 m
0.35 m
0.085 m
0.325 m
0.38 m
0.115 m
Note
You can use the Copy object function to speed up the creation of the remaining objects after pipe1 and joint1 are created. However, the names will not be the same as the tutorial. To rename an object, right mouse click the object in the Model tree and click Rename. 3. Next, we will also build the heat sink using block objects. Build the base and one pin according to the following
0.44 m
0.38 m
0.067 m
0.04 m
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Chapter 6: Heat-Pipe Modeling and Nested Non-Conformal Meshing Plane: XZ Non-uniform radius Note that the non-uniform radius option is in the Geometry tab as shown below and that the Plane option is X-Z (Figure 6.3 (p. 112)). Solid material: default
Make two copies of Pin with an offset of 0.033 m in the Z direction (i.e., Number of copies= 2, Translate with Z offset = 0.033 m). Highlight the three tapered fins (Pin, Pin.1 and Pin.2), make four copies of this highlighted group with an offset of 0.033 m in the X direction (i.e., Number of copies = 4, Translate with X offset = 0.033 m).
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Step 3: Create Nested Non-conformal Mesh Using Assemblies Group all the pins by highlighting them in the model tree, click on the right mouse and select Copy and finally make one copy as follows: Number of copies = 1, Translate with Y offset = -0.03, Mirror with Plane: XZ and About: Low end. The final model should appear as shown in Figure 6.4 (p. 113).
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Chapter 6: Heat-Pipe Modeling and Nested Non-Conformal Meshing a. b. c. d. e. f. Highlight all the pins and the base in the model tree. Right mouse click and select Create then Assembly. Rename the assembly as Heatsink-asy. Double click on the assembly to open the Edit panel. Under the Meshing tab, toggle on the Mesh separately button. Set the slack to the following values:
Note
For the Heatsink-asy, we have set a bounding box that is 0.005 m bigger than the assembly at five sides except Min Z where the slack is defined higher (0.015m) to capture the wake region of the flow. g. h. i. Click Update and Done. Following the same procedure above, create two more assemblies; one for vent.1 (name it Ventasy) and one for the fan (name it Fan-asy). Use the following tables to assign slack values for Vent-asy and Fan-asy assemblies, respectively.
Put the previously created assemblies into an outer assembly covering all. a. b. c. d. Highlight all the three assemblies above and click the right mouse button. Select Create assembly. Rename this main assembly HS-vent-fan-asy. Assign the following slack values to the assembly.
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Step 5: Physical and Numerical Settings Min Y Min Z 0.02 m 0m Max Y Max Z 0.02 m 0m
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Chapter 6: Heat-Pipe Modeling and Nested Non-Conformal Meshing 2. Go to the Transient setup tab and set the initial condition for the velocity in the z-direction to be -0.1 m/s to achieve faster convergence (If there is an initial guess at the start of the solution there is a lesser chance of large initial velocities in the first iteration). These two steps are shown in Figure 6.6 (p. 116). Click Accept for these changes to take effect.
3.
4.
Click Accept.
b. c. d. 2.
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Step 9: Summary
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7.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in ANSYS Icepak and that you have solved Sample Session in the Icepak User's Guide and the tutorial "Finned Heat Sink". Some steps in the setup and solution procedure will not be shown explicitly.
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Source Create a source using the following dimensions: Object source.1 Geometry: Rectangular Plane: X-Z xS = 0.48 m yS = 0.52 m zS = 0.48 m xE = 0.52 m yE = zE = 0.52 m Specification Total power: 30 W
Heat sink Now, create a heat sink with the following geometrical and physical properties. Tab Geometry Settings Plane: X-Z Start/end xS = 0.46 m, xE = 0.54 m yS = 0.50 m, yE = zS = 0.40 m, zE = 0.6 m Base height: 0.02 m Overall height: 0.1 m Properties Type: Detailed Flow direction: Z
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Chapter 7: Non-Conformal Mesh Detailed fin type: Cross cut extrusion Fin setup/Fin spec: Count/thickness Count: 8 in Z-dir and 8 in X-dir Thickness: 0.01 m in Z-dir and 0.004 m in X-dir Flow/thermal data: default base and pin material The screen shots of the heatsink panel is shown in Figure 7.3 (p. 124).
Note
The minimum gap for X, Y, Z might adjust to 10% of the minimum dimension in respective directions. Make a note of the number of elements, the minimum face alignment and the aspect ratio. 2. Examine the mesh.
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Step 4: Physical and Numerical Settings a. b. c. d. Click the Display tab. Turn on the Cut plane option. In the Set position drop-down list, select Y plane through center. Turn on the Display mesh option.
Note
The mesh display plane is an x-z plane cut through the center of the cabinet as shown in Figure 7.4 (p. 125). Note the clustered mesh lines extending from the heat sink all the way across the domain in both the x and z directions. The total number of cells is about 144000.
3.
Turn off the mesh display. a. b. Deselect the Display mesh option. Click Close to close the Mesh control panel.
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Chapter 7: Non-Conformal Mesh Click Reset in the Basic settings panel. Check the values printed to the Message window. The Reynolds and Peclet numbers are approximately 12600 and 8900, respectively, so the flow is turbulent. To set up turbulent flow, go to Problem setup Basic parameters and choose the Zero equation turbulence model under the General setup tab. Click Accept to accept the new solver settings. Basic settings and set the Number of iterations to 300. Go to AdGo to Solution settings vanced settings and specify Under-relaxation factors for Pressure, Momentum, and Temperature as 0.7, 0.3, and 1.0 respectively. Define a monitor point by dragging the source object (source.1) into the Points folder. This creates a monitor point for temperature of the object, which can be used to judge convergence.
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e.
ANSYS Icepak opens the Report summary data panel, where minimum, maximum, and mean temperatures for the heat sink and source are displayed. Note that the maximum temperature is about 36.7 C.
2. 3.
Click Done to close the Report summary data panel. Click Close to close the Define summary report panel.
Note
Because you are changing the current model, thereby invalidating the post-processing data that has been loaded from the previous steps, you will need to generate a mesh (a nonconformal mesh) and calculate the solution again which is shown in steps 9 through 11.
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Chapter 7: Non-Conformal Mesh 1. Create an assembly consisting of the source and the heat sink objects. a. b. c. 2. Click the Create assemblies button ( ) to create a new assembly. This creates an assembly node in the Model manager window under the Model node. Select the source.1 item under the Model node in the Model manager window, hold down the Ctrl key, and then select the heatsink.1 item. Hold down the left mouse button, drag both highlighted items into the assembly.1 node of the tree, then release the left mouse button.
Edit the assembly and define its bounding box. a. b. c. Select the assembly.1 node in the Model tree, and then click the Edit object button ( the Assemblies panel. Click the Meshing tab. Turn on the Mesh separately option and enter the Slack parameters shown in Figure 7.5 (p. 128). ) to open
Figure 7.5 Slack Values and Mesh Controls in the Separately Mesh Assembly
This creates a bounding box region that is 0.05 m larger than the assembly on four sides. Since Min Y is already at the bottom of the cabinet, no slack value can be provided for it. A larger slack value of 0.15 m has been provided in the Max Z direction to resolve the wake region. Not that a smaller Max X and Max Z grid size has been specified within the assembly compared to the global max grid size. This helps to refine the mesh within the separately meshed assembly. 128
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Step 9: Generate a Non-conformal Mesh d. Click Done to set the properties of the assembly and close the panel. The new model is shown in Figure 7.6 (p. 129).
Figure 7.6 The Source and Heat Sink in a Separately Meshed Assembly
Note
Make a note of the number of elements, the minimum face alignment, and the aspect ratio. 2. Examine the mesh.
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Chapter 7: Non-Conformal Mesh a. b. c. d. Click the Display tab. Turn on the Cut plane option. In the Set position drop-down list, select Y plane through center. Turn on the Display mesh option. The mesh display plane is an - plane cut through the center of the cabinet as shown in Figure 7.7 (p. 130). Note the clustered mesh lines extending from the heat sink all the way across the domain in both the and directions only within the bounds of the assembly. The total number of cells is about 107000.
3.
Turn off the mesh display. a. b. Deselect the Display mesh option. Click Close to close the Mesh control panel.
Step 13: Summary 2. Start the Solution. Solve Run solution a. b. Specify non-conformal as the solution ID. Click Start solution to start the solver.
Note
The monitor point that you already created is automatically used for the new solution. The solution converges after about 175 iterations. Note, however, that the exact number of iterations required for convergence may vary on different computers.
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8.2. Prerequisites
The trainee should be familiar with: ANSYS Icepak modeling objects Basics of meshing Non-conformal meshing
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Chapter 8: Mesh and Model Enhancement Exercise Work with this model for as long as you prefer within the allocated 15 minutes and STOP. Proceed to the next set of instructions.
Hint
Start by generating the mesh without any changes. View mesh cut planes at various orientations and locations to identify root causes that result in unnecessary mesh clusters in noncritical regions. Then modify the model in order to tackle the issues you notice.
Note
Ensure the meshing type is Mesher-HD. Create mesh cut planes in different orientations to identify the root cause for such a high mesh count. One such cut plane (Z plane through center set position) is shown in Figure 8.1 (p. 135). Figure 8.1 (p. 135) shows that the high mesh count is due to grid bleeding from the heat sink and the components cooled by it.
Note
What feature in ANSYS Icepak allows you to avoid grid bleeding?
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Figure 8.1 A Mesh Cut Plane View of the Given Model When Meshed Without Modifications
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Tip
Shift + left mouse click and draw a window around the group of objects you would like to assemble. You can make the mesh and some objects invisible to select the heat sink objects. You can also select the objects in the Model manager window by left mouse clicking heatsink.1 and then Shift + left mouse clicking HS_component.
2.
We will test two non-conformal assembly options: a regular non-conformal assembly (with slack values) and a zero slack non-conformal assembly.
Note
It is recommended to use the Case check macro to ensure a thin conducting plate is not intersecting a non-conformal assembly. In the Macros menu, select Case check> Automatic Case Check Tool. Click the Apply button for the following options: Assembly intersection check and Thin Conducting Plate and Assembly Intersections. If there is an intersecting plate, the slack value should be changed to get rid of this error. b. c. Generate the mesh again. Observe the decrease in element count with every modification you make. The mesh count should be around 315,000 cells.
Note
Zero slack non-conformal assembly resulted in fewer mesh count than the regular nonconformal assembly intersecting thin conducting plate. This limitation will be resolved in the next step.
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Chapter 8: Mesh and Model Enhancement Exercise Even though you are only interested in isolating the hi-flux-comps", there are two cylindrical objects very close to it. You have two choices. 2. 3. 4. Avoid the cylinders by using zero slack value. This may be too small and create a small gap between the interface and the cylinders, which is not desirable. Include the cylinders to the assembly. This is the suggested approach.
Create a zero slack non-conformal assembly that includes the hi-flux-comps, Tabs, Dies, and adjacent cylinders. Note that the Tabs and Dies are contained within the hi-flux-comps. Generate the mesh again. Repeat cut plane viewing. Figure 8.3 (p. 138) shows a cut plane view after creating the two separate mesh regions.
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This method of creating a super assembly containing sub-non-conformal assemblies is called nested non-conformal meshing" or recursive embedded meshing". Revisiting the Separation Setting By default, ANSYS Icepak's accepts all minimum gap changes. We shall revisit these changes now. In the Mesh control panel, set all the Minimum gap settings to 0.0001 m. In the Misc tab, uncheck Allow minimum gap changes. Generate the mesh. The pop-up message as shown in Figure 8.5 (p. 139) will appear.
This warning appears because the separation (think of it as a tolerance setting for the mesher) distance is larger than 10% of the smallest feature in the model. When there are objects smaller than the mesher tolerance, those objects will not be meshed correctly. However, note that the separation setting is a useful tool designed to avoid unnecessary meshes due to inadvertent misalignments in the model (without modifying the geometry). Look for the name of the object featured in the warning and its dimension. Why should you model an object that's 0.1 mm in thickness? Is it likely to improve the accuracy of your results?
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Chapter 8: Mesh and Model Enhancement Exercise Do not accept the suggested change to the separation settings.
Generate the mesh again. This time you will see another separation warning about the AL-spreader. Again, do not accept the changes.
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Conclusion
Note
It is also possible to use a separation distance larger than the recommended 10% value. Values of up to 50% (of the smallest dimension) may be used in cases where reducing the mesh count is critical. You will now get a separation warning about the tabs. We cannot change the geometry of the tabs, so accept the suggested change in separation settings again. Here are some suggested qualities of meshes: The size of the first cells from critical heat dissipating surfaces should be less than 1 mm for a 1st cut analysis. View mesh cut plane on the wall of the enclosure object, the PCB and the critical heat generating components to see if you are fulfilling the above requirement. Use the Object params control to request mesh refinement near all the important surfaces mentioned above. Generate the mesh to see if your request is being honored. Finally, a comparison... For comparison purposes, deactivate the Mesh assemblies separately option in the Mesh control panel and generate the mesh. The difference between the mesh with this check button active and inactive is the effect of non-conformal meshing. STOP: Solution and post processing are beyond the scope of this exercise. Please compare the suggested approach with the approach you were attempting during the initial 15 minute period of this tutorial.
8.14. Conclusion
A model with room for improvement is provided. Using approximate object choices and meshing strategies, the model and the mesh were improved. The approach delineated in this exercise can help reduce significant run time without compromising the physics being modeled.
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9.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in ANSYS Icepak and that you have solved or read the tutorial "Finned Heat Sink". Some steps in the setup and solution procedure will not be shown explicitly.
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2.
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Save the problem to a new project file. This enables you to expand on the problem without affecting the original file. File Save project as 1. 2. In the Project text box, enter the name loss-coefficient-new. Click Save.
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Note
The velocity at the inlet opening in terms of the Reynolds number (), which is customarily used in loss-coefficient plots in lieu of velocity, is calculated as = , where the kinematic viscosity = 1.5843e-5 kg/m.s, and the hydraulic diameter of the duct Dh = 9.322e-3 m. a. b. c. Select the inlet opening, cabinet_default_side_minx, in the Model manager window, and then click the Edit object button ( ) to open the Openings panel. Click the Properties tab. Select X Velocity and set the value to $Re*1.5843e-5/9.322e-3.
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d. e.
Click Done to set the properties of the opening. This opens the Param value panel. Set the Initial value of Re to 10, and click Done to close both the Param value and the Openings panels.
2.
Define six trials according to the different values of the Reynolds number. Solve Define trials a. b. In the Parameters and optimization panel, make sure Parametric trials and All combinations are enabled in the Setup tab. Click on the Design variables tab, enter the following values for the Reynolds number in the box next to Discrete values: 10 50 100 500 1000 1750. Click Apply to accept the changes.
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Note
Parameters values can also be exported/imported by clicking the Export or Import button in the Setup tab of the Parameters and optimization panel. Clicking Export or Import opens a file selection dialog box and overrides any existing data.
c.
Click the Trials tab to review the trials. Make sure the Trials across top option at the bottom of the tab is disabled, and click Reset to select Values instead of Numbered in order to use the base names as values.
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d. 3.
Define the report that displays average velocity and pressure data at the inlet and outlet openings. Solve Define report
Note
The loss coefficient is obtained by dividing the total pressure differential through the domain by the average dynamic pressure, = a. b. c. d. e.
In the Define summary report panel, click New. In the Objects drop-down list, select cabinet_default_side_maxx and click Accept. In the Value drop-downlist, select UX. Repeat steps (a) and (b), then select Pressure in the Value drop-down list. Repeat steps (a) through (d) for cabinet_default_side_minx.
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f. 4.
Click the Close button to accept the settings and close the panel.
Set the parametric trials and define primary and compound functions. Solve Run optimization a. b. c. d. In the Parameters and optimization panel, click the Setup tab. Verify that the Parametric trials and All combinations options are turned on. Click the Functions tab. Define four primary functions (Pstat_in, Pstat_out, Uave_in, and Uave_out).
Note
These functions represent static pressures and velocities at the inlet and outlet, respectively. i. ii. iii. iv. Under Primary functions, click the New button to open the Define primary function panel. In the Define primary function panel, enter Pstat_in for the Function name. Select Report summary from the Function type drop-down list and cabinet_default_side_minx Pressure from the Item drop-down list and retain the selection of Max. Click Accept to accept the changes and close the panel.
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v.
Repeat steps (i) through (iv) for the following three functions: Function name Pstat_out Function type Report summary Item cabinet_default_side_maxx Pressure cabinet_default_side_minx UX cabinet_default_side_maxx UX Max/Mean Max
Uave_in Uave_out
Mean Mean
Important
All function names are case-sensitive. 5. Define five compound functions (Pdyn_in, Pdyn_out, Ptot_in, Ptot_out, and Kfact). a. b. c. Under Compound functions, click the New button to open the Define compound function panel. In the Define compound function panel, enter Pdyn_in for the Function name. Next to Definition enter 0.5*1.1614*$Uave_in*$Uave_in.
d. e.
Click Accept to accept the changes and close the panel. Repeat steps (a) through (d) for the following four functions: Function name Pdyn_out Definition 0.5*1.1614*$Uave_out*$Uave_out
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6.
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Note
The mesh display plane is an - plane cut through the center of the cabinet as shown in Figure 9.3 (p. 154).
3. 4.
Deselect the Display mesh option to turn off the mesh display. Click Close to close the Mesh control panel.
Keep the default selection of Flow(velocity/pressure) under Variables solved. Keep the default selection of Laminar for the Flow regime. Click Accept to close the panel.
Enter 500 in the Number of iterations field. Click Accept in the Basic settings panel.
3.
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Step 8: Examine the Results The Advanced solver setup panel opens. a. b. Confirm that the Under-relaxation factor for Pressure is 0.7 and for Momentum is 0.3. Click Accept in the Advanced solver setup panel.
Note
button in the Model and solve toolbar to display Alternatively, you can click the the Parameters and optimization panel. 2. 3. Make sure Allow fast trials (single .cas file) is unchecked in the Setup tab. Click Run in the Parameters and optimization panel.
Plot the loss coefficient, Kfact, against the Reynolds number, Re. 1. In the Parametric trials panel, click the Plot button to open the Selection panel.
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Chapter 9: Loss Coefficient for a Hexa-Grille 2. In the Selection panel, select Re as the axis variable, and click Okay.
3.
In another Selection panel, which automatically opens up, select Kfact as the y axis variable, and click Accept. This displays the plot Kfact vs Re, as shown in Figure 9.4 (p. 156)
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10.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in ANSYS Icepak and that you have solved or read Tutorial Finned Heat Sink (p. 3). Some steps in the setup and solution procedure will not be shown explicitly.
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Note
When ANSYS Icepak starts, the Welcome to Icepak panel will open automatically. 3. Click Unpack in the Welcome to Icepak panel.
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Note
The File selection panel will appear. 4. In the File selection panel, select the packed project file heat-sink2b.tzr and click Open.
Note
The Location for the unpacked project file selection dialog will appear. 5. In the Location for the unpacked project file selection dialog, select a directory where you would like to place the packed project file, enter a project name in the New project text field, then click Unpack.
Note
You can rotate the cabinet around a central point using the left mouse button, or you can translate it to any point on the screen using the middle mouse button. You can zoom into and out from the cabinet using the right mouse button. To restore the cabinet to its default orientation, select Home position from the Orient menu. Save the problem to a new project file.
Note
This will allow you to expand on the problem without affecting the original file. File Save project as In the Project name text box, enter the name heat-sink-new. Click Save.
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b. c. d.
Right-click the Active check box to open the Active parameter panel. Select ON if variable is equal to this object's name. Enter $HeatSink in the Variable text box.
Caution
Note that all function names are case sensitive.
e. f.
Click Accept in the Active parameter panel to accept the changes and close the panel. Click Update in the Assemblies panel to open the Param value panel.
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Chapter 10: Inline or Staggered Heat Sink g. In the Param value panel, enter Staggered for the Initial value of HeatSink, and click Done to close the panel.
Note
The word Active in the Assemblies panel became green. Also, note that the Inline assembly in the Model manager window is moved to the Inactive node. h. 2. a. Click Done in the Assemblies panel to close the panel. Repeat above steps for the Staggered assembly.
Note
You will not have to specify the initial value again.
Extra
Alternatively, you can click the 1. Define parameter values. a. b. c. In the Parameters and optimization panel, click the Design variables tab. Next to Discrete values, after "Staggered" type in "Inline". Make sure to separate the two with a space. Click Apply to accept the changes. button.
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2.
Review trials. a. b. c. Click the Trials tab. Make sure that the Order for Staggered is 1, and for Inline is 2. Select tr_HeatSink_Staggered as the Restart ID for the tr_HeatSink_Inline trial as shown in the image below.
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3.
Define a primary function. a. b. Click the Functions tab. Click the New button in the Primary functions group box.
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c. d. e.
In the Define primary function panel, enter Tmax next to Function name. In the Value drop-down list, select Maximum temperature of objects. In the Object drop-down list, select the 700_BGA_40X40_5peripheral_p1.50 object in the Package assembly, and click Accept.
f. g.
In the Define primary function panel, click Accept to save the changes and close the panel. Click Done in the Parameters and optimization panel to close the panel.
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Chapter 10: Inline or Staggered Heat Sink Model Generate Mesh 1. 2. 3. 4. Make sure that the Mesh type is Hexa unstructured. In the Global tab, make sure that the Mesh assemblies separately option is turned on. Keep all other defaults in the Mesh control panel. Click Close in the Mesh control panel to close the panel.
Set the Number of iterations to 300. Click Accept in the Basic settings panel to accept the settings and close the panel.
Note
You can click the 2. 3. button in the Model and solve toolbar.
Click the Setup tab, and make sure that options Parametric trials and All combinations are selected. Deselect Allow fast trials (single .cas file). Click Run in the Parameters and optimization panel, to start the calculations.
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Note
As ANSYS Icepak starts calculating solutions for the model, the Solution residuals window, displaying convergence history, and the Temperature Point monitors window will open. Also, the Parametric trials panel will open displaying the function values, as well as parameters and running times for both trials, as shown in Figure 10.2 (p. 167). The Parametric trials can also be opened by selecting Show optimization/param results from the Report menu.
Extra
You can also open the Plane cut panel by clicking the a. b. c. d. e. f. In the Name field, enter the name cut_velocity. In the Set position drop-down list, select Vertical - screen select. Select a point in the graphics window between the fan and the heat sink assembly. Turn on the Show vectors option, and click Parameters to open the Plane cut vectors panel. In the Plane cut vectors panel, in the Color levels group box, select This object from the Calculated drop-down list. Check Project to plane. button.
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g. h.
Click Done in the Plane cut vectors panel to accept the changes and close the panel. In the Orient menu, select Isometric view.
Note
The graphics window will be updated, as shown in Figure 10.3 (p. 168)
Figure 10.3 Velocity Vectors at the Exit Region of the Heat Sink
3.
Move this plane cut through the model. a. b. Hold down the Shift key, press and hold down the middle mouse button on the edge of a vector. Drag the plane cut through the model in the graphics display window.
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4.
Clip the plane cut to align it with the sides of the heat sink assembly. a. b. c. d. e. f. g. h. i. In the Orient menu, first select Orient positive X, then Scale to fit. Unexpand the Inline assembly node in the Model manager window if it was expanded in order to see the edges of the assembly in the graphics window. In the Plane cut panel (that was already opened), select Enable clipping, then click Max Y in the orange region under Clip to box. Click the top edge of the assembly in the graphics window. In the Plane cut panel, click Min Z in the orange region under Clip to box. Click the left edge of the assembly in the graphics window. In the Plane cut panel, click Max Z in the orange region under Clip to box. Click the right edge of the assembly in the graphics window. Click the Update button.
Note
The graphics window will be updated, as shown in Figure 10.4 (p. 170)
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5.
Display particle traces in a forward direction. a. b. c. d. e. f. g. h. In the Orient menu, select Isometric view. In the Plane cut panel, unselect Show vectors and Enable clipping and select Show particle traces. Click Parameters next to Show particle traces to open the Plane cut particles panel. Select Speed from the Variable drop-down list. In the Display options group box, keep the default selection of Uniform, and enter 50. In the Style group box, keep the default selection of Dye trace and select Particles with Radius 2. In the Color levels group box, select This object from the Calculated drop-down list. Click Done to update the graphics window.
Note
The graphics window will display the particle traces in the forward direction, as shown in Figure 10.5 (p. 171)
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6.
Display particle traces at the opening (Xmax). a. b. c. d. e. f. g. h. i. j. k. l. In the Orient menu, select Orient negative Z. In the Plane cut panel, deselect Active and click New. In the Name field, enter the name opening-velocity. In the Set position drop-down list, select Vertical - screen select. Select a point in the graphics window near the opening (Xmax). This point will should be around 0.814 on the slider bar. Turn on the Show particle traces option, and click Parameters to open the Plane cut particles panel. Select Speed from the Variable drop-down list. In the display options group box, keep the default selection of Uniform, and enter 50. In the Style group box, keep the default selection of Dye trace and select Particles with Radius 2. In the Color levels group box, select This object from the Calculated drop-down list. Click Done in the Plane cut particles and Plane cut panels to close the panels and update the graphics window. In the Orient menu, select Isometric view.
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11.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in ANSYS Icepak and that you have solved or read the tutorial "Finned Heat Sink". Some steps in the setup and solution procedure will not be shown explicitly.
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2.
Note
You can rotate the cabinet around a central point using the left mouse button, or you can translate it to any point on the screen using the middle mouse button. You can zoom into and out from the cabinet using the right mouse button. To restore the cabinet to its default orientation, select Home position from the Orient menu. Save the problem to a new project file (this enables you to expand on the problem without affecting the original file). File Save project as 1. 2. In the Project name text box, enter the name optimization-new. Click Save.
Important
All function names are case-sensitive. e. In the Param value panel, enter 12 for the Initial value of finCount, and click Done to close the panel.
f. g.
In the Heat sinks panel, under the Fin setup tab, type $finThick next to Thickness, and press Enter on the keyboard to open the Param value panel. In the Param value panel, enter 0.762 for the Initial value of finThick, and click Done to close the panel.
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h. 2.
Specify the constraint values for the design variables. Solve Run optimization
Extra
Alternatively, you can click the a. button.
Turn on the Optimization option in the Setup tab. Then click on the Design variables tab.
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The design variables that you had defined will be listed in the panel, and their initial values will be shown in the Base value text box. b. c. d. e. f. Select finCount from the list, then enter 2 for the Min value constraint, 18 for the Max value constraint. Select Allow only multiples, keep the default value of 1, and click Apply. Select finThick from the list, then enter 0.254 for the Min value constraint, 2.032 for the Max value constraint, and click Apply. Make sure Allow only multiples is only activated for finCount, not finThick. Click Done to close the Parameters and optimization panel.
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Solution settings 1. 2. 3.
Make sure Number of iterations is 125. Make sure the convergence criteria for Flow is 0.001, and for Energy is 1e-7. Click Accept to close the Basic settings panel.
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Step 7: Define Primary, Compound, and Objective Functions ii. iii. iv. v. vi. b. i. c. In the Define primary function panel, enter bighsrth next to Function name. In the Function type drop-down list, keep the default selection of Global value. In the Value drop-down list, select Thermal resistance of heatsink. In the Object drop-down list, select the heatsink_big object under hs_assembly_2, and click Accept. In the Define primary function panel, click Accept to save the changes and close the panel. Repeat step (a) for the bighsms as the Function name, Global value as the Function type, Mass of objects as the Value, and heatsink_big as the Object. Repeat step (a) for the smlhsms as the Function name, Global value as the Function type, Mass of objects as the Value, and heatsink_small as the Object. Click the New button under Primary functions. In the Define primary function panel, enter mxtmp next to Function name. In the Function type drop-down list, keep the default selection of Global value. In the Value drop-down list, keep the default selection of Global maximum temperature. Select Constraint and keep the default selection of Max value. Enter 70 in the text entry field and click Accept to save the changes and close the panel.
Define the mass function for the large heat sink (bighsms).
Define the mass function for the small heat sink (smlhsms). i.
d.
Define a constraint function as the global maximum temperature of 70C (mxtmp). i. ii. iii. iv. v. vi.
3.
Define a compound function. a. Under Compound functions, click the New button to open the Define compound function panel.
b. c. d. e. 4. a. b.
In the Define compound function panel, enter totalmass for the Function name. Next to Definition enter $bighsms+$smlhsms. Select Constraint and keep the default selection of Max value. Enter 0.326 in the text entry field and click Accept to save the changes and close the panel. In the Parameters and optimization panel, select bighsrth from the Objective function dropdown list. Keep the default selection of Minimize value.
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Note
Alternatively, you can click the 2. Set up the optimization process. a. b. c. In the Parameters and optimization panel, click the Setup tab. Verify that the Optimization option is turned on, and keep all the defaults for this option. Deselect Allow fast trials (single .cas file). button in the Model and solve toolbar.
Note
Due to the geometry change based on the fin thickness and fin count, the fast trials option is not possible in this problem.
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Step 9: Examine the Results d. Select Sequential solution of flow and energy equations.
3.
Click Run in the Parameters and optimization panel to start the calculations.
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Note
Each iteration takes three trials.
Primary functions
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Step 11: Additional Exercise Thermal resistance for the large heat sink (bighsrth) Mass of the large heat sink (bighsms) Mass of the small heat sink (smlhsms) Maximum temperature for the entire system: 70C (mxtmp) Total mass of the heat sinks: 0.45 kg (totalmass) Minimize the large heat sink thermal resistance (bighsrth)
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12.2. Prerequisites
This tutorial assumes that you have worked on Sample Session in the Icepak User's Guide and the tutorials "Finned Heat Sink" and "RF Amplifier" in this guide.
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Figure 12.1 Dimensions of the Cabinet and the Boundary Condition Specifications
2. 3. 4. 5.
In the Properties tab of the Cabinet panel, define all the sides of the cabinet as shown above. The min y and max y sides are defined as openings while all the remaining sides are stationary walls. Click Done to close the Cabinet panel. The printed circuit board (PCB), heat sink base and the fins of the heat sink will be constructed using the block object in ANSYS Icepak. Create the PCB. a. b. First, create a block and rename it as PCB in the Info tab of the Blocks panel. Specify the dimensions of the block in the Geometry tab as shown below in Figure 12.2 (p. 187).
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c. 6. a. b. c.
Click Done to close the Blocks panel. Right-click the Model node and select Create object and then Material. A new node called Materials will open. Expand the Materials node until you reach material.1. Double click material.1 to open the Materials panel. In the Properties tab of the Materials panel, choose Orthotropic from the Conductivity type drop-down list. i. Enter 40, 40, and 0.4 W/m-K for the X, Y, and Z directions, respectively. Click Done to close the Materials panel. In the Model manager window, double click the PCB object we created to open the Blocks panel again. In the Properties tab of the Blocks panel, pick material.1 from the Solid material drop-down list. Click Done to close the Blocks panel. Create a new block and rename it as hs-base in the Info tab of the Blocks panel. Specify the dimensions of the block in the Geometry tab as shown below in Figure 12.3 (p. 188).
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d. e. f. g. 7. a. b.
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c. 8. a. b.
Click Done to close the Blocks panel. Create a new block and rename it as hs-fin.1.1 in the Info tab of the Blocks panel. Specify the dimensions of the block in the Geometry tab as shown below in Figure 12.4 (p. 189).
Note
The units depicted in Figure 12.7 (p. 192) are in mm and m.
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c. d.
Leave all the other properties as their default values. Click Done to close the Blocks panel. To complete the creation of the remaining fins we will use a copy procedure. i. ii. iii. iv. Right click the hs-fin1.1 object in the Model manager window and select Copy. The Copy block hs-fin.1.1 panel opens. Set Number of copies to 8. Check the Translate option and set the X, Y and Z offset to 15, 0, and 0 mm respectively. Click Apply to close the Copy block hs-fin.1.1 panel and create the new fins.
9.
Create a 75W 2D source. a. b. c. Create a source using the Create sources button in the model toolbar. In the Sources panel, specify the geometry and properties of the source according to Figure 12.5 (p. 190). Click Done to close the Sources panel and complete the creation of the model.
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Tip
Alternatively, you can use the snapping tool from the object geometry area to snap the source dimensions to those of the min z side of the hs-base block object.
The final model should appear as shown in Figure 12.6 (p. 191).
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Note
The units depicted in Figure 12.7 (p. 192) are in mm and m.
c. 3.
Once the assembly creation is complete, open the Mesh control panel by pressing the Generate mesh button. a. b. Change the Mesh units to mm. Input the Max element size specifications according to Figure 12.8 (p. 193).
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c. d. e. f. g.
Keep all other parameters as their default values. Make sure Allow minimum gap changes is checked under the Misc tab. Press Generate to create the mesh. You can view the mesh using the Cut plane and Surface options available in the Display tab. Once you have finished viewing the mesh, make sure you uncheck Display mesh in the Display tab, and click Close to close the Mesh control panel.
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Chapter 12: Radiation Modeling iv. Make sure that the Radiation option is turned Off.
b.
Under the Defaults tab i. In the Ambient conditions group box, set the Temperature and the Radiation temp to 40C. Enter a small velocity value for the Y velocity such as 0.01 m/s.
c.
Note
In free convection flow problems, setting a small initial velocity opposite to the gravity vector direction is suggested. ii. d. 2. Retain the defaults for all other settings in the Basic parameters panel. Solution settings
Go to a. b. c.
Set the Number of iterations to 400 Make sure the Flow is 0.001 and the Energy is 1e-7 in the Convergence criteria group box. Click Accept to close the Basic settings panel. Solution settings Advanced settings.
3.
Go to
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Step 5: Solving the Model Without Radiation a. b. In the Advanced solver setup panel specify the Under-relaxation parameters of 0.7 and 0.3 for Pressure and Momentum, respectively. Select Double from the precision drop-down list at the bottom of the panel (Figure 12.10 (p. 195)).
c. d.
Keep all other default options in the Advanced solver setup panel. Press Accept to close the Advanced solver setup panel.
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Note
You can check the maximum temperatures of each object by going to Report Solution overview Create.
To model radiation effects go to Model Radiation form factors or use the radiation icon ( open up the Form factors panel. a. b.
Under Participating objects, select all objects by clicking All and leave all other settings to their default values. Press Compute to calculate the view factors. i. ii. iii. You can display the view factors calculated by clicking each participating object listed under Display object values. After reviewing the view factors, select Don't recompute. The settings for the view factor calculations setup are shown in Figure 12.11 (p. 197).
c.
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3. 4.
Go to Solve Run solution and start the solver with S2S as the solution ID. Once the solution residuals have converged, make note of the maximum temperature.
Enable the Discrete ordinates radiation model option in the Radiation group box. Press Accept to close the Radiation panel.
Start the solution again with DO as the solution ID. Once the solution residuals have converged, make note of the maximum temperature.
Enable the Ray tracing radiation model option in the Radiation group box. Press Accept to close the Radiation panel.
Start the solution again with Ray as the solution ID. Once the solution residuals have converged, make note of the maximum temperature.
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Chapter 12: Radiation Modeling there is reasonable agreement in the plane cut post processing objects obtained using the different radiation models. Figure 12.12 (p. 199) compares the temperature fields for all the four cases.
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Figure 12.12 Plane cuts on the z = 20 mm plane for (a) Radiation disabled (b) S2S radiation model (c) Discrete ordinates radiation model and (d) ray tracing radiation model
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Chapter 12: Radiation Modeling Discrete ordinates Ray tracing 76.38C 75.63C
Note
The actual values may differ slightly on different machines, so your values may not look exactly the same. In most models, the use of the surface to surface (view factors) model is strongly recommended. The discrete ordinates model should be used only for very complex geometries where there are many surfaces and computation of the view factors can become extremely computationally expensive. This is also true when there are CAD objects present in the ANSYS Icepak model. The ray tracing model is also for complex geometries and for objects that have large temperature variations.
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13.2. Prerequisites
This tutorial assumes that you have worked on Sample Session in the Icepak User's Guide and the first two ANSYS Icepak tutorials of this guide.
3.
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Open the Cabinet object panel, go to the Properties tab, under Wall type, change Min y and Max y to Opening. Press Done and then Shift+I for an isometric view. Plate Object plate.1 Geometry: Rectangular Plane: X-Y xS = 0.1 m yS = 0.2 m zS = 0.12 m xE = 0.3 m yE = 0.4 m Specification Solid material: default (Al-Extruded) Thermal model: Conducting thick: 10 mm
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Step 2: Build the Model Blocks Object block.1 Geometry: Cylinder Plane: X-Y Nonuniform radius Radius2 0.012m IRadius2 0.0 xC 0.15 m yC 0.25 m zC 0.13 m Height 0.06 m Radius 0.02m IRadius 0.0 Specification Block type: Solid Solid material: default (Al-Extruded)
Make two copies of the tapered fin (block.1), offset by 0.05 m in the X direction (i.e., Number of copies = 2, and Translate with X offset = 0.05 m). Select all three tapered fins, and make two copies of this group with an offset of 0.05 m in the Y direction (i.e., Number of copies = 2, and Translate with Y offset = 0.05 m). Remember to right mouse click on the icon in the Model tree to copy objects. These tapered cones model a heat sink with tapered cone fins. Sources The four sources have a peak power of 100 Watts each with a cycle time of 20 seconds. The variation of power is according to the following exponential curve, = , where and is the time. Object source.1 Geometry: Rectangular Plane: X-Y xS = 0.12 m yS = 0.22 m zS = 0.12 m xE = 0.18 m yE = 0.28 m Specification Total power = 100 W
Create a source (source.1) per the specification in the table above. In the Properties tab of the Sources panel, toggle on Transient, click Edit, and enter 0 for Start time and 20 for End time. To specify the variation curve, click on Exponential and set a = 0.025 and b = 100. Click Update and Done, in the Transient power panel, and then the Sources panel.
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Now make one copy of source.1 with an offset of 0.1 m in the X-direction. Select source.1 and source.1.1, then make one copy of these two sources with an offset of 0.1 m in the Y-direction to complete the construction of the sources. Basic To view the time-dependent power specified for the sources, go to Problem setup parameters. Select the Transient setup tab and click on View (next to Edit parameters) near the top of this panel. This displays the time variation of the power specified using sources.
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Figure 13.3 Viewing the Variation of Power on the Sources with Time
A time dependent power profile such as a piecewise linear curve can also be imported/exported by clicking Load All/Save All in the Transient panel. Clicking Load All will open the Load all curves file selection dialog box and override any existing data. Select the CSV file containing the curve data and click Open. The final model should appear as that shown in Figure 13.4 (p. 206).
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Note
The Init element height feature can be used in a relatively simple model as this one. It is not recommended to be used for complex models as this can create very large mesh count.
Flow regime, and toggle on the default Gravity vector (i.e., X = 0, Y = -9.80665 m/s2, Z = 0). In the Transient setup tab, give a small initial (global) velocity of 0.001 m/s in the Y direction. Accept the changes made and exit this window.
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Step 8: Generate a Summary Report Go to Solution settings Basic settings and click on Reset to examine the estimated Rayleigh Advanced settings and set the Under-relaxation number. Then go to Solution settings factors to 0.7 for Pressure and 0.3 for Momentum. Press Accept to close the panel. In the Basic settings panel, set Iterations/ timestep to 100. The number of iterations per time-step should be sufficient for the solution to converge at each time-step. Press Accept to close the panel.
Create a point monitor to monitor the temperature change with time by dragging and dropping source.1 into the Points folder in the Model tree.
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Step 9: Examine the Results Object Specifications Contours of: Temperature Contours options: Solid fill Shading options: Smooth Color levels: Calculated/Global limits Post Transient settings: Time step: 1 or Time value: 0 Forward or Backward cut.1 Set position: Z plane through center Show vectors/Parameters Color by: Velocity magnitude Transient: Same as the above To animate the above post objects, go to Post Transient settings to open the Post-processing time panel. Click on Animate to open the Transient animation window. To animate the current display on screen, click on Animate in the Transient animation panel. The animation can be played once, from the start time to end-time, or in the Loop mode. In addition to animating the display in screen, you can also write the animation to a file in MPEG, GIF, and some other neutral formats to be saved and played back later using a third party software. To do that, go to Post Transient settings, then click Animate to open the Transient animation panel. Toggle on Write to file, then click Write to open the Save animation panel. Pick a file format, give it a file name, and then Save. This sequence saves the entire display area with no scaling. Alternatively, you can click on the Options tab in the Save animation panel and modify the Scale factor in the Save animation options panel. Also available in Save animation options panel is Print region. Choose the default Full screen or Mouse selection. Choosing Mouse selection allows one to draw a rubber band and select only a part of the screen. To do so, choose Mouse selection, specify the file type and file name, then click on Save in the Save animation panel. With the cursor showing a square and the red prompt at the bottom of the screen, draw a rectangular region with the left mouse to save it to the animation file. You can examine how a variable changes over time at selected points using the History plot panel. To open this panel, select History plot in the Post menu or click ( ) in the Postprocessing toolbar. Observation: The view shows air flowing from one opening to the other. Also notice that the velocity distribution changes with time. Description
In the History plot panel, enter 20 seconds for End time, click the Add point button and select source.1 for the point. Click the Create button to display the plot shown in Figure 13.7 (p. 210).
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Once the results have been loaded into CFD-Post, there are several options to view and analyze a transient solution. 1. Display time history similar to what is displayed in Icepak. a. b. c. d. e. f. Go to Insert Text Enter the text, Auto Annotation . In the Definition tab of the Details view, enter Time . Enable the Embed Auto Annotation option. In the Type drop-down list, select Timestep. Click Apply.
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2.
Create a contour. a. b. Go to Insert Contour and create a new contour named TemperatureContours. Update the settings for the Geometry tab of the Details view for TemperatureContours as shown in Figure 13.10 (p. 213) and click Apply to create the contour (Figure 13.11 (p. 214).
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3.
Display temperature at different time steps. a. ) to display the Timestep Selector panel. Double click a Click the timestep selector icon ( timestep to view the corresponding temperatures. See Figure 13.12 (p. 215) for details.
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Additional options that are available in CFD-Post can be found in "Postprocessing Using ANSYS CFDPost".
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14.2. Prerequisites
This tutorial assumes that you have little experience with ANSYS Icepak and ANSYS Workbench, but that you are generally familiar with the interface. If you are not, please review Sample Session in the Icepak User's Guide and the tutorial "ANSYS Icepak - ANSYS Workbench IntegrationTutorial" of this guide.
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2.
Copy ICEPAK_ROOT/tutorials/rack/rack.tzr to your working directory. You must replace ICEPAK_ROOT by the full path name of the directory where ANSYS Icepak is installed on your computer system. Drag an Icepak template from the Toolbox into the Project Schematic. Right mouse click the Icepak Setup cell and select Import Icepak Project From .tzr. Select Browse... and the File selection panel appears. Select the packed project file rack.tzr and click Open. The CAD model appears in the graphics display window. Click the isometric toolbar icon ( the isometric view of the model. ) to display
3. 4. 5.
6.
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Chapter 14: Zoom-In Modeling in ANSYS Workbench 1. 2. In the Project text box, enter the name rack-new. Click Save.
Note
ANSYS Workbench will close Icepak to save the model, you will need to launch Icepak again to continue.
In the Mesh control panel, make sure Hexa unstructured is selected as the Mesh type. Set the Max element size for X, Y, and Z to 0.03 m if not already set. Select the Normal option next to Mesh parameters. In the Local tab, select Edit next to Object params (Figure 14.3 (p. 221)). Verify that the individual localized mesh settings for the following objects are: Object type Openings Plates Block Object name All openings All plates block.3 Parameter Y count Low end height High end height Y count Requested Value 10 0.003 0.003 4
Note
You can also set mesh parameters by right clicking object in the Model tree and selecting Edit mesh parameters.
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6. 7.
Press Done to close the Per-object meshing parameters panel. In the Settings tab of the Mesh control panel, Generate the mesh and then display and check the mesh quality from the Display tab. Uncheck the Display mesh option when you are done.
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Chapter 14: Zoom-In Modeling in ANSYS Workbench 2. 3. Go to Problem setup Basic parameters and make sure the Flow regime is Turbulent and the turbulence model is Zero equation under the General setup tab. Press Accept to close the panel. Now add two temperature point monitors for plate2.1 and plate2.2 into the Points folder to observe the progress of the solution at the center of the objects. To do this, highlight both objects in the Model tree using the Ctrl key and the left mouse button, and then drag objects into the Points folder. The default setting for a monitor point is temperature so nothing else has to be done.
Note
When gravity is not turned on in the solution, you have the opportunity to reduce solve time if desired by selecting this option. Since there are no buoyancy effects, there is no longer a coupling of the Navier-Stokes and energy equations. Thus, you can completely converge the flow equations and then use that value in the energy equation instead of solving both on every iteration. 2. Click Start solution to run the solver.
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Step 7: Examine the Results Object Specifications Show particle traces/Parameters Variable: Speed Display options: Uniform = 50 Style: Dye trace and Particles cut.1 Plane location: Set position: Z plane through center Show vectors cut.2 Plane location: Set position: X plane through center Show vectors face.1 and cut.1 should look similar to Figure 14.4 (p. 223) and Figure 14.5 (p. 224). Plane cut (y-z) view of the velocity vectors in the x plane. Observation(s): Flow patterns (especially around the plates) Plane cut (x-y) view of the velocity vectors in the z plane. Observation(s): Flow patterns (especially around the plates) Description Observation(s): Animate the particle traces. If you want to see motion from start to end, turn off particles and animate the traces.
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2.
Finally, save all the postprocessing objects created. Go to Post Save post objects to file. Save it with default file name post_objects to be used in future.
2.
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Note
The coordinates for each of the zoom-in boundaries can also be specified by clicking the Select button to the right of the appropriate text entry box and clicking the left mouse button on the desired point in the graphics display window. You may want to orient your view depending upon the coordinate being selected to ensure a more accurate selection. The boundaries of the zoom-in model will be displayed in the graphics window as you update them.
3.
Click on Accept to create the zoom-in model. Since many of the parts in the zoom-in model extend out of the zoom-in box, a warning message window should appear listing a set of objects that lie outside. In the Objects overlapping dialog box, click the Resize button to resize these parts to fit into the zoom-in model. ANSYS Icepak writes out a zoom-in model called rack-new.zoom_in. ANSYS Icepak reports on the operations to construct the model and creates the profiles in the ANSYS Icepak messages window.
4.
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Step 9: Edit the Zoom-in Model thick plate to represent the components. We can now replace the plate.2.2 by the individual components. 4. Double click plate.2.2 to open the Plates panel and make the following changes: Field Info Name Geometry Specify by YL ZL Properties Power 5. Create nine additional components in an array. a. b. c. d. e. f. Right mouse click Chip and select Copy. Create two copies of Chip with an Z-offset of -0.065 m. Select and highlight all three Chip plates in the Model tree. Make three copies of the three plates with an Y-offset set to 0.07 m in the same way you copied the singe chip. View the geometry in isometric view (Shift+I). Delete two of the components to form the pattern shown in Figure 14.8 (p. 228). 3.0 W Start / length 0.05 m -0.05 m Chip Value
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The meshing panel should now look like Figure 14.9 (p. 229).
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4.
Generate the mesh and then display and check the mesh quality from the Display tab. Make sure to uncheck the Display mesh option when you are done.
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Chapter 14: Zoom-In Modeling in ANSYS Workbench Object Specifications Contours of: Temperature Contours options: Solid fill Shading options: Smooth Calculated: This object face.2 Object: side_opening.miny Show particle traces/ Parameters Variable: Speed Particle options Start time: 0; End time: 1 Display options: Uniform = 100 Style: Dye trace and Particles Figure 14.10 (p. 231) shows the two object faces at the same time. Object-face showing the flow pattern Observation(s): Note the flow pattern on both sides of plate1.2 and over the components. Animate the particle traces. Description
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Chapter 14: Zoom-In Modeling in ANSYS Workbench You can then perform a comparison study in CFD Post by setting up a third Icepak component. This time duplicate the first Icepak component and link this component to the available Results component. Post process the results in CFD Post and compare them to the results containing the PCB plate object.
3. 4. 5. 6. 7. 8.
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Figure 14.11 Temperature Comparison: Zoom-in vs. System with Non-conformal assembly
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15.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in ANSYS Icepak and that you have solved or read the tutorial "Finned Heat Sink". If you have not, please review Sample Session in the Icepak User's Guide.
2.
Click New in the Welcome to Icepak panel to start a new ANSYS Icepak project. The New project panel appears.
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Chapter 15: IDF Import 3. Specify a name for your project. a. b. In the Project name text box, enter the name idf-demo. Click Create.
1.
In the IDF import panel, click the Browse button next to the Board file (ascii) field and select the file (brd_board.emn). Board files have the extension *.emn" or *.brd". Note that the library file (brd_board.emp) gets loaded automatically. Specify Project Name as tutorials/idf_import (Figure 15.2 (p. 236)).
2.
Click Next and go on to the Layout options section (Figure 15.3 (p. 237)). Retain all default settings:
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Step 2: Build the Model Import type as Detail Board plane as XY - this is always detected automatically Board shape as Rectangular Board properties - Click Edit button to access the Board properties where you can enter details such as number of trace layers, coverage and layer thickness etc. Layer properties refer to the average properties of all internal layers. In this example, examine the defaults, and click Cancel to close the Board properties panel.
Note
More advanced PCB models are covered in the introductory tutorial, "RF Amplifier", and application tutorial, Trace Layer Import for Printed Circuit Boards (p. 267) located in this guide. Drilled holes are for positioning purposes and usually are not thermally important. During the import, they can be ignored. By default, ANSYS Icepak leaves import drilled holes unchecked under Detailed options. Enable Make all components rectangular under Detailed options to convert all polygonal components to prisms.
3.
Click Next to go to the Component filters section (Figure 15.4 (p. 238)). Components can be filtered either by size and power or by component type. For now, select Filter by component type and Import all components. The other options will be explained in more detail at the end of the tutorial.
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4. 5.
Click Next to go to the Component models section (Figure 15.5 (p. 238)). Select Model all components as and keep the default settings. The option Choose specific component model will be discussed later in the tutorial.
6.
Click on Next to go to the Miscellaneous options section (Figure 15.6 (p. 239)). Select Append Part Name to Reference Designator under the Naming conventions group box.
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7. 8.
Click Finish to complete the import. Examine the imported model (Figure 15.7 (p. 240)). Observe: the different types of blocks the material properties of the PCB block, which is called BOARD_OUTLINE.1 the power and resistance values of the network blocks, if any.
Note that: The components form into groups according to types automatically You can use the edit function under groups to change properties for all the components in the same group at one time You should check message windows for missing properties.
Figure 15.7 (p. 240) shows ANSYS Icepak model with components modeled as 3D objects (solid blocks or two-resistor network blocks). Appropriate boundary conditions need to be applied before starting thermal analysis. In addition, you can review power values by selecting the Power and temperature limit option in the Model menu.
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2.
If Filter by component type is chosen (Figure 15.9 (p. 241)), the required components can be selected through the Component selection panel (Figure 15.10 (p. 241)); otherwise all the components are included. The Component selection panel contains reference designators for all components.
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Figure 15.9 IDF Import Panel - Component filters: Filter by component type
After clicking Choose, you can choose individual components from the panel in the figure below:
3.
Figure 15.11 (p. 242) shows a sample file. Objects not present in the file are imported with data already present in the IDF file, or as solid blocks with no power specification.
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4.
Component properties may also be edited manually by selecting the Specify values for individual component types option. The components to be imported are listed under Selected components. The component name is composed of the type and name and the number of copies, followed by a more descriptive part name (Figure 15.12 (p. 242)). To manually set the component property, you can select the component in the Selected components list. Multiple selections can be made with Ctrl + left mouse or Shift + left mouse. Then, you can choose the model type: Two-resistor (Rjc-Rjb), 3d blocks, or 2d sources, and specify power. For a two-resistor model, Rjc and Rjb values need to be specified as well. After inputting your specifications, you can click Apply to complete the modification.
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Step 5: Summary updated in the ANSYS Icepak model. Components filtration and modeling alternatives that are available in the IDF import mechanism, were also discussed.
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16.2. Prerequisites
This tutorial assumes that you have little experience with ANSYS Icepak, but that you are generally familiar with the interface. If you are not, please review Sample Session in the Icepak User's Guide.
The heat sink used for this sample problem was obtained from the company Alpha, www.alphanovatech.com/cindexe.html#w.
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Figure 16.1 Wind Tunnel Model with Heatsink Modeled as CAD Block
2.
Click New in the Welcome to Icepak panel to start a new ANSYS Icepak project. The New project panel appears.
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3.
Specify a name for your project. a. b. In the Project name text box, enter the name shapes. Click Create.
Note
ANSYS Icepak creates a default cabinet with the dimensions 1 m 1 m 1 m and displays the cabinet in the graphics window.
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d. 2. a. b. c. d.
The CAD model appears in the graphics display window. In the Creation mode section of the CAD data panel, ensure Selected is enabled. Select Use CAD surfaces directly. In the Create object section, select Blocks. Drag a rectangular region around the displayed CAD model to select the surfaces to be used to create the CAD block. Clicking on the middle mouse button creates the block (e.g., F_4074 or similar name) which can be used in the ANSYS Icepak model. In the CAD data panel, under Families, click None to hide all CAD lines and surfaces.
In the CAD data panel, select the surfaces to be used to create the CAD block.
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e. 3.
In the Cabinet object panel, click the Geometry tab. Under Location, enter the Start/end coordinates shown in Table 16.1: Coordinates for the Cabinet (p. 249) :
Important
Note that the dimensions are in mm.
Click Update to resize the cabinet. In the Orient menu, select Isometric view to scale and orient the view of the cabinet to fit the graphics window (Figure 16.2 (p. 250)).
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Figure 16.2 Creating the Heat Sink CAD Block From a CAD File
4.
Edit the cabinet properties to specify the Min x and Max x sides as openings. a. b. Select Opening from the drop-down menu under Wall type for Min x and Max x. Select Edit to display the Openings object panel for Min x and specify the velocity to be 5 m/s.
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c. 5.
Press Done in the Openings object panel and then the Cabinet object panel to apply the changes and close the panels.
Create a block at the base of the heat sink. a. Click the Create blocks button ( ) to create a new block.
ANSYS Icepak creates a new solid prism block in the center of the cabinet. You need to change the size of the block. b. c. d. Click the Edit object button ( Click the Geometry tab. Enter the Start/end coordinates for the Prism block as shown in Table 16.2: Coordinates for the Block (p. 252). ) to open the Blocks panel.
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Important
Note that the dimensions are in mm.
The block touches the cabinet in the Min y direction, and the heat sink in Max y. The Min z and Max z sides of the block touch the cabinet. e. In the Properties tab, select Solid for the Block type if not already selected. Under Thermal specification, keep default as the Solid material. Because the default solid material is extruded aluminum, you need not specify the material explicitly here. Click Done to modify the block and close the panel.
f. 6.
Create a source between the base block and the heat sink. a. b. Click the Create sources button ( ) to create a source.
Edit the source Geometry with the Start/end dimensions given in Table 16.3: Coordinates for the Source (p. 252).
Important
Note that the dimensions are in mm.
Edit the source Properties and specify a Total power of 50.0 Watts.
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d.
Click Done to modify the source property and close the panel.
Note
We will allow heat transfer from the base of the metal block by creating a wall, wall.1 on the Min y side of the block and the cabinet boundary. 7. Create a wall at the base of the metal block. a. Edit the wall Geometry with Start/end dimensions given in Table 16.4: Coordinates for the Wall (p. 253).
Important
Note that the dimensions are in mm.
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Chapter 16: Modeling CAD Geometry b. Edit the wall Properties to specify the boundary conditions of the wall. i. ii. iii. iv. Select Heat transfer coefficient from the External conditions drop-down list. Press Edit to open the Wall thermal conditions panel. Select Heat transfer coeff in the Thermal conditions group box. Input a Heat transfer coeff of 10 W/km2 and keep the default selection of Constant in the Heat transfer coefficient group box. The Reference temperature is ambient.
v.
Press Done in the Wall external thermal conditions panel and then the Walls object panel to apply the changes close the panels.
The final model should correspond to the one shown in Figure 16.1 (p. 246).
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Important
Note that the dimensions are in mm.
Note
The slacks in the Min Z and Max Z directions are specified by snapping with the cabinet boundary in the respective directions. Note the use of Max element size in each direction to control the mesh refinement in the assembly. c. Press Done to close the Assemblies panel.
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Chapter 16: Modeling CAD Geometry 2. Another separately meshed assembly, assembly.2 is created with assembly.1 to enable a smooth transition of the fine mesh in assembly.1 to the relatively coarse mesh in the outer regions of the model. a. b. Choose assembly.1, block.1 and wall.1 from the Model tree and create assembly.2. The meshing parameters for this assembly are shown in Figure 16.5 (p. 256).
Important
Note that the dimensions are in mm.
Note
There is a larger max grid size in this assembly compared to assembly.1. c. 3. a. Press Done to close the Assemblies panel. Keep the default selection of Mesher-HD for the Mesh type and input the settings shown in Figure 16.6 (p. 257) below.
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Important
Note that the dimensions are in mm.
Note
When meshing models containing CAD blocks, you could select Hexa unstructured or Hexa cartesian for the global Mesh type, but only Mesher-HD should be used to mesh CAD blocks. Therefore, you must create assemblies with Mesher-HD as the Mesh type around all the CAD blocks. b. 4. Click Generate to create the mesh.
The surface mesh on the heat sink and the mesh on the center y" plane is shown in Figure 16.7 (p. 258). The relatively coarse mesh in the overall cabinet, the intermediate mesh in assembly.2 and the fine mesh in assembly.1 is clearly seen in the central y" plane view of the mesh as shown in Figure 16.8 (p. 258).
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Note
This is a forced convection problem; therefore the natural convection as well as radiation effects can be ignored.
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Step 4: Physical and Numerical Settings b. c. Switch off the Radiation and make sure Gravity vector is unchecked. Choose Turbulent and then Zero equation in the Flow regime group box.
Note
The problem being dominated by forced convection, a sequential solution of flow and energy equation shall be used. d. 2. Press Accept to save the settings and close the panel.
Under Solution settings Basic settings, specify the number of iterations to 300, the Flow convergence to 0.001 and the Energy convergence to 1e-14, as shown in Figure 16.9 (p. 260), and press Accept to save the settings and close the panel.
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3.
Stringent energy convergence criterion is required when the energy equation is solved separately. Go to a. b. Solution settings Advanced settings.
Make sure that the Under-relaxation parameters for Pressure and Momentum are 0.3 and 0.7 respectively. Input the following for Temperature in the Linear solver group box: i. ii. Choose W from the Type drop-down list. Enter 1e-6 for the Termination criterion and the Residual reduction tolerance.
c.
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Note
These settings are used for separate solution of the energy equation d. Press Accept to save the changes and close the panel.
Note
You can click the save project button ( ) in the File commands toolbar.
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Note
The actual values of the residuals may differ slightly on different machines, so your plot may not look exactly the same as Figure 16.11 (p. 262).
c. 262
Choose the CAD block from the Object drop-down list Click on Show contours and then Parameters to open the Object face contours panel. Keep the default selection of Temperature in the Contours of drop-down list. Keep the default selection of Solid fill in the Contours of group box. Select Smooth in the Shading options group box. Keep the default selection of Calculated in the Color levels group box and choose This object from the drop-down list.
g.
Press Done in the Object face contours panel and then in the Object face panel to close the panels and view the postprocessing object.
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Chapter 16: Modeling CAD Geometry This maps the color range to the temperature distribution on the heat sink. The temperature on a given point can be seen using the surface probe tool. Figure 16.13 (p. 264) shows the temperature distribution on the heat sink.
2. 3.
Right click face.1 in the Model tree and deselect Active to deactivate the postprocessing object. Click the Plane cut button ( a. b. c. ) under the Postprocessing toolbar.
Select Y plane through center from the Set position drop-down list. Select Show vectors option. Click Create and Done. Zoom in to display more details.
The velocity field around the heat sinks fins, visualized on the central y -plane, is shown in Figure 16.14 (p. 265).
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Step 8: Summary
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17.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in ANSYS Icepak and that you have solved or read the tutorial "Finned Heat Sink". Some steps in the setup and solution procedure will not be shown explicitly.
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2.
Click New in the Welcome to Icepak panel to start a new ANSYS Icepak project. The New project panel appears.
3.
Specify a name for your project. a. b. In the Project name text box, enter the name trace-import. Click Create.
2.
Select Next to see your Layout options. Keep Detail for the Import type, XY for the board plane and Rectangular for the board shape.
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Note
Because we import the trace information later, we do not need to edit the board properties at this time. 3. Select Next to see the Component filtering options. Ensure Import all components is selected.
Note
You can filter certain components at this step by their size and power information, i.e. you can ignore the small components or the ones dissipating low power. We will import all of the components in this tutorial. 4. Select Next to see the Component models section. Select Model all components as. Keep the default selection of 3d blocks and the default Cutoff height for modeling components as 3d blocks.
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Note
If you have thin components on your board, they can be modeled as 2D sources. In this tutorial, we would like to model all the components as rectangular blocks. 5. Click Next to go to the Miscellaneous options section where you can specify the naming and monitor options. Keep the default options and click Finish to start importing the files. This will take some time depending on the speed of your machine.
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You have learned how to import board and library files, and in general you can import any IDF file by using the procedure above. The next step in building the model is to import the trace files. A pre-built board model named A11" (see Figure 17.1 (p. 271)) will be used to demonstrate the trace file import. This pre-built model was extracted from the previous board file (A11.brd), a number of small components were removed and a non-conformal assembly was formed.
a.
Unpack A11.tzr file to your desktop and name the project A11".
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Note
As mentioned earlier, the trace file (.brd, .tcb, .mcm, .anf, or .odb++) can either be imported during the IDF file import or the trace layout information can be assigned to the board after importing the IDF file. b. Right click BOARD_OUTLINE.1 in the Model manager window and click Edit to display the Blocks object panel. To import the trace layout, follow the procedures below. i. In the Geometry tab, select ASCII TCB from the Import ECAD file drop down list (Figure 17.2 (p. 272)).
ii. iii.
Select A1.tcb from the Trace file panel. This process may take a few minutes depending on the speed of your computer. Once the import process is completed, you can edit the layer information in the Board layer and via information panel (Figure 17.3 (p. 273)). The number of layers in the board will automatically be imported to ANSYS Icepak and you will have to enter the thickness of each layer and the material type. In this tutorial, the metal layers are pure Cu and the dielectric layers are FR-4.
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Step 2: Build the Model iv. Enter the layer thickness as shown in Table 17.1: Thickness Information on the Board (Layer 1: Top, Layer 7: Bottom layers) (p. 273) and choose 100 rows and columns.
Table 17.1 Thickness Information on the Board (Layer 1: Top, Layer 7: Bottom layers)
Layer Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 Layer 6 Layer 7 Thickness (mm) 0.04 0.45364 0.062 0.467 0.055 0.442 0.045
v.
By default, layers are lumped for each sub-grid, therefore, the Model layers separately option is off. They can also be modeled separately, which will be discussed later when the Model layers separately option is used.
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Chapter 17: Trace Layer Import for Printed Circuit Boards vi. Via information (e.g., material, plating thickness, filled/un-filled, via diameter etc.) is imported automatically (Figure 17.4 (p. 274)), keep the default settings.
Note
The background mesh matrix (rows and columns) is used to compute the orthotropic conductivity on the board. The rows represent the division of the board in the y-direction, the columns represent the division of the board in the x-direction and the size field determines the divisions of the board and indicates the grid size in each direction. The values of k, kx, ky, and kz on each cell are determined by the local trace density and the direction. ANSYS Icepak does not include the trace geometry in the physical model; however, the locally varying orthotropic conductivity is mapped from the background mesh to the physical model mesh. Once the trace file is imported and assigned to the board geometry, the trace layers are associated with the board and are moved (in translation and/or rotation) with the board object.
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Step 2: Build the Model viii. Press Done to close the Blocks object panel. ix. Right click on the object BOARD_OUTLINE.1 and go to Traces from the menu.
Note
You can view the traces in three different ways, i.e. single color, color by layer, or color by trace. Each of the trace layers can be viewed separately by switching the visible option on or off in the layers part of the panel. (Figure 17.5 (p. 275)).
x.
Select color by trace; the board traces are as shown in Figure 17.6 (p. 276).
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Figure 17.6 Trace Layout on the PCB with the Color by trace Option
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Note
The rest of the sides are insulated. The board will be simulated using a conductiononly model. 6. 7. Press Done to close the Cabinet panel. Go to Model Generate mesh to open the Mesh control panel. a. b. c. 8. Make sure the Mesh type is Mesher-HD. Specify a Max element size for X, Y, and Z as 5, 3, and 0.05 mm respectively, and a Minimum gap of 1 mm in all three directions. Keep all other defaults and click Generate.
Once the mesh has been created, Close the Mesh control panel.
Go to a. b.
Keep the default Number of iterations and set the Convergence criteria for Energy to 1e-12. Click Accept to close the panel. Solution settings Advanced settings.
3.
Go to a. i. ii. b. c.
Input the following for Temperature in the Linear solver group box: Choose W cycle from the Type drop-down list. Enter 1e-6 for both the Termination criterion and Residual reduction tolerance.
Select Double for the solver Precision. Press Accept to close the Advanced solver setup panel.
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The mid-plane temperature distribution shows that the high temperature regions occur at the no-trace areas and low temperature regions occur at areas with a high trace concentration. This is expected as the copper content is directly proportional to the trace concentration. It is worth noting that if a compact or detailed PCB were used in lieu of the traced PCB, one would obtain a fixed temperature for the entire mid-plane and this fixed temperature would be different from the average temperature of the traced PCB on the same plane.
Note
The spatially varying non-uniform conductivity of the board can also be viewed during post processing. The conductivities in the three direction K_X, K_Y, and K_Z are available as postprocessing variables with plane cuts and object faces. Figure 17.8 (p. 279) plots kx at the board mid-plane by selecting K_X from the Contours of drop-down list from Plane cut contours panel of the cut.1 object. In the present case, because we chose not to model the layers separately, there will be no variation of the conductivities in the board-normal direction.
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2. 3.
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Chapter 17: Trace Layer Import for Printed Circuit Boards While not shown here, the trace import feature has a number of advantages on the meshing side. It should be remembered that detailed PCB's cannot intersect non-conformal assemblies; however, there is no such limitation for block objects. Since a PCB is represented as a block in the case of importing traces, non-conformal assemblies can intersect it. 4. 5. Open the Mesh control panel and choose X, Y, Z sizes as 9.5, 7, and 0.7 mm respectively. Keep all other defaults and Generate the mesh.
2. 3.
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Figure 17.9 Top Surface Temperature Distribution: PCB With Imported Traces (100 x 100) in Forced Convection
7.
Note
The Model layers separately option automatically creates contact resistance plates in the plane of the board at the start and end locations of each metal layer. These dummy plates have zero thermal resistance and their sole purpose is to ensure proper mesh resolution within the board. Figure 17.10 (p. 282) shows the plates created for the tracing layers on this board. To model each of the layers separately we need to ensure that there is at least one cell across each of the metal and dielectric layers at the correct locations in the board-normal direction.
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Figure 17.10 Contact Resistance Plates for Meshing the Individual Layers Separately
7.
Now the model can be meshed again same mesh settings as earlier except for the Minimum gap in the Z direction, which should be set to 0.25 mm to account for the contact resistance plates, and solved with the exact same boundary conditions. The temperature distribution and conductivity profiles on the board can be viewed again during post processing to examine the effect of modeling the layers separately as compared to the previous case.
17.18. Summary
In this tutorial, you imported the board layout and trace files. Then you simulated the board using a conduction only model. Postprocessing this model showed high temperature regions occurring at the no-trace areas and low temperature regions occurring at areas with a high trace concentration. Then you simulated the board with the components put back into the model and simulated under forced convection. Then you simulated the conduction using the Model layers separately option.
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18.2. Prerequisites
This tutorial assumes that you have completed Tutorial Trace Layer Import for Printed Circuit Boards (p. 267) of this guide. This same model is used to determine the joule/trace heating capability in ANSYS Icepak.
Note
When ANSYS Icepak starts, the Welcome to Icepak panel will open automatically. 2. Click Unpack in the Welcome to Icepak panel to start a new ANSYS Icepak project.
Note
The File selection panel will appear. 3. In the File selection panel, select the packed project file joule-heating.tzr and click Open.
Note
The project file can be found in your installation directory at ICEPAK_ROOT/tutorials/joule-heating/joule-heating.tzr.
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Chapter 18: Joule/Trace Heating 4. In the Location for the unpacked project panel, select a directory where you would like to place the packed project file, enter a project name in the New Project text field, and click Unpack.
Note
The Trace heating panel lists the traces in each layer in order of descending area, see Figure 18.1 (p. 285). ii. Before you create a solid trace of Trace 1_1724, you need to modify the Max angle filter and the Min length filter to ignore the fine details in the trace geometry and reduce the mesh count. If not already selected, select Trace 1_1724 and set the Max angle filter to 135 and the Min length filter to 1.0 mm.
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iii.
Click on the Create solid trace button. ANSYS Icepak will create a polygonal solid block named BOARD_OUTLINE.layer-3-trace-1_1724 that contains the trace information. (The actual name may vary). Click Done to close the Trace heating panel.
Note
You can try reducing the Area filter to 1000 mm2 to check how many traces appear. We are interested in the second largest trace, trace 1_1724. b. 2. a. Click Done in the Blocks panel to close the panel and view the model. In the Geometry tab of the Blocks panel, make sure there are around 60 vertices for the trace, as shown in Figure 18.2 (p. 286).
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Select the polygonal trace from the Model tree and open the Blocks panel.
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b.
Go to the Properties tab. i. Make sure that the Solid material is tr_1_1724_sol_mat and then select Edit definition in the drop-down list. A. B. C. The Materials panel opens. Make sure the Properties tab of the Materials panel looks like Figure 18.3 (p. 287). Press Done to close the Materials panel.
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ii.
In order to activate Joule heating of the trace, press the Edit button for the Joule option. The Joule heating power panel opens. A. B. For the first boundary condition in the Boundary conditions group box, set Side to side1, Boundary type to current, and specify the Current to 25 Amps. For the second boundary condition, set Side to side42, Boundary type to voltage, and the Voltage to 0 V.
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Note
Current conservation needs to be manually inspected by the user.
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Figure 18.5 Entry and Exit Sides for the Trace Block
Note
The side numbers are estimates as they may be slightly different for each model. C. Press Done in the Joule heating power panel and then the Blocks panel to close the panels and view the model.
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Note
Ensure Mesh type is Mesher-HD. c. 2. a. b. c. d. e. Press Done to close the Assemblies panel. Make sure the Mesh type is Mesher-HD. Keep the global settings under the Max element size group box as 9, 5, and 0.75 mm, for X, Y, and Z respectively. Set the Minimum gap as 0.75, 0.45, and 0.035 mm for X, Y, and Z, respectively. Generate the mesh. Check the mesh quality for the trace and the overall model from the Display and Quality tabs.
Step 7: Examine the Results b. 2. Press Done to close the panel. Problem setup Basic parameters.
Go to a. b.
Since this is a forced convection problem, ensure that the Flow is toggled on and that Turbulent is selected under Flow regime. Select Zero equation as the turbulence model. Press Accept to close the panel. Solution settings Basic settings.
3.
Go to a. b. c.
Make sure the Convergence criteria for Flow is 0.001. Set the Number of iterations to 200 and the Convergence criteria for Energy and Joule heating to 1e-8. Press Accept to close the panel. Solution settings Advanced settings.
4.
Go to a. i. ii. b. c.
Input the following for Temperature in the Linear solver group box: Choose W cycle from the Type drop-down list. Enter 1e-6 for both the Termination criterion and Residual reduction tolerance.
Make sure the Precision for the solver is Double. Press Accept to close the Advanced solver setup panel.
d.
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2.
Now plot the electric potential of the same trace, Figure 18.8 (p. 293).
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a. b. c.
Click on Parameters to open the Object face contours panel. Select Electric Potential from the Contours of drop-down list and press Apply. Observe the contours. Do you observe any similarity between the temperature and the electric potential contours?
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Chapter 18: Joule/Trace Heating d. The temperature contours are closely related to the electric potential contours, which is a direct result of joule heating of the trace.
Press Done in the Object face contours and Object face panels to close the panels.
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19.2. Prerequisites
This tutorial assumes that you have worked on Sample Session in the Icepak User's Guide and the first two ANSYS Icepak tutorials of this guide.
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2. 3. 4. 5.
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PCB
1.6 mm thick, FR4 Material, six 1 oz. layers of Copper, 30% coverage for all layers Extruded Aluminum
Heat Spreader for TO-220 packages TO-220 Packages DIP 400 PBGA (new package type to the existing board) 232 PQFP (new package type to the existing board)
3 9 6 6 2
= 2.5 C/W
None See Table 19.2: Available Information for 400 PBGA 232 leads, 40 mm X 40 mm Footprint, 2 mm height
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Note
An ounce of Copper is actually the thickness of 1 ounce/sq.ft of plane copper sheet. Using copper density this translates to a thickness of 0.035 mm.
Create the PCB ). Then edit the Create a PCB object by clicking on the Create printed circuit boards button ( PCB by clicking the Edit object button ( ) while the PCB object is selected in the Model tree. Enter the following in the Geometry tab: Object type Name Shape/Type/Plane Global Coordinates (m) XS YS ZS XE YE ZE PCB a. b. pcb.1 XZ 0.0 0.0 0.0 0.25 NA 0.2
Go to the Properties tab. Enter the PCB thickness of 1.6 mm for Substrate thickness. Change the default unit from micron to Cu-oz/ft2 for high and low surface thickness and for internal layer thickness under Trace layer parameters section.
2.
Material information for the PCB is in Table 19.1: Available Details for Objects in the Model (p. 297). This information can be entered for the selected PCB object as shown in Figure 19.3 (p. 299).
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Figure 19.3 PCB Edit Form with input based on PCB information in the Table with Model Object Details above
Now, you should see the PCB object overlapping the block called PCB. There is no more need for this block.
Note
You recreated the PCB object geometry using coordinates of the imported PCB block. 3. 4. Deactivate the block named PCB". Heat spreader for TO-220 devices a. Since default solid material happens to be extruded aluminum, all three spreaders should have come into the model with correct material specification. Check this information by editing the objects.
5.
Modeling Packages This model has four different types of objects. Based on available information and our objectives, we shall use different compact package modeling capabilities in ANSYS Icepak.
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Chapter 19: Microelectronics Packages - Compact models a. TO220 Type Packages i. There are 9 TO-220 device blocks. Select them all at once by drawing a window" with Shift+left mouse (see Figure 19.4 (p. 300)). Press Shift+I for an isometric view. Simultaneous selection can also be done in the Model manager window, press the Ctrl key and left mouse click to select objects.
ii.
You should see all TO-220 devices highlighted in the tree. Please note that only TO-220 objects should be selected. If you see other objects highlighted (such as the Spreader objects), please deselect them by holding down the Ctrl key and left mouse clicking them in the tree. You can simultaneously edit all of the remaining objects at once by clicking your right mouse on any one of the selected TO-220 objects in the tree. A. B. C. Select Network for the Block type. Keep the default selection of Two Resistor for the Network type. In order to assign the resistance, we need to identify a reference side. This is the purpose of board side" input. We want the resistance to be applied from Junction to the side in contact with the spreader (Max Z side). We can accomplish this in two ways: Designate Min Z side as the Board side and assign the supplier provided resistance value (2.5 C/W from Table 19.1: Available Details for Objects in the Model (p. 297)) to Rjc. OR Designate Max Z side as the Board side and assign the supplier provided resistance value to Rjb.
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Note
Zero resistance means that there would not be any link and the resistance values are infinite. D. Input 1.5 W for the Junction power.
iii. b. i. ii.
Click Done to finish the operation. As we did before for the TO_220 objects, select all the DIP objects and simultaneously edit them. Use default solid material (any material will work because we are not interested in DIP temperature). A. B. Input 0.5 W in the Total Power field. Click Done
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Note
Dip is the package type for which we have the least information. So we are left with two options: Try to get information from supplier. OR Perform a tentative simulation with available information. The options are considered along with the following facts: The DIPs constitute a lower heat flux than the other components in the board. This is an existing design in which the DIPs have been known to run well below their specified temperature even at max power.
Based on the above reasoning, it is easier to perform a tentative simulation with the available power information than to obtain the information from the supplier. In this context the purpose of the DIP package modeling is to appropriately account for air and PCB heating due to flow over the DIPs. Accurate prediction of the DIP temperature is not an objective. c. PQFP package modeling Internal details are unavailable for the PQFP type package. But based on the exterior details such as lead count, foot print size, and package height information, it is possible to construct a compact model of a typical package for screening analysis. i. Go to the Libraries node by clicking the Library tab in the Model manager window. Then right-click Libraries and select Search packages.
Note
A package may also be created using either IC package macros or a package object.) ii. In the Search package library panel enter all known information about the package (Table 19.1: Available Details for Objects in the Model (p. 297)) as search criteria. Clicking the Search button should return 1 the closest matching packages from the library. Pick the package that is most similar in description to the 232-lead PQFP information available and select Create. Figure 19.6 (p. 303) depicts the package search procedure.
If search does not return a relevant package, click on the package object icon to create a new package object. After entering the few known values, you may enter reasonable values or leave the remaining parameters as defaults.
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iii.
Go back to the Project tab and edit the created package object. Make sure that: The Package type is QFP. The Package thickness is 2.0 mm. The Model type is Compact Conduction Model (CCM). The Symmetry is Full.
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Note
CCM is a compact model based on geometric simplifications that still preserve the original heat transfer pathways of the package. It has been demonstrated
2
that CCM is fairly accurate and boundary condition independent. Other options under Model type are: To model the package in full detail. This option is meant for package level modeling. Using this in board or system design will unduly complicate the simulation. To characterize Junction-to-case and Junction-to-board network resistances for a two resistance compact model. We will be doing this for the PBGA package.
iv. v. vi.
Select the Die/Mold tab. (The Substrate and Solder tabs show blank interface since QFP type packages do not have solder or substrate). Enter 3.5 W for Power. Use all other defaults under Die/Mold tab. Click Done to close the tab. The package created is in an arbitrary location. You may use the Align face centers button ( ) to position the base center of the created package object with that of the 232PQFP block. The dimensions of the package should match the dimensions of the 232PQFP block:
vii. There is no more need for the 232PQFP block. Deactivate it. viii. There is another 232PQFP" block (232PQFP.1). Create a copy of the first package object and align with the remaining 232PQFP" block. Then, deactivate the second 232PQFP" block (232PQFP.1). The dimensions of the second package should be:
d.
PBGA package modeling We have fairly comprehensive information about the PBGA type package from the supplier (see Table 19.2: Available Information for 400 PBGA (p. 298)). Using this information we can construct a CCM or characterize to determine jc and jb to model it as a 2-resistor network model as shown here: i. Select all the blocks named 400-PBGA and edit all of them simultaneously. A. B. Select Network as the Block type and Two resistor as the Network type. Set the board side as Min Y.
Karimanal, K.V. and Refai-Ahmed, G., Validation of Compact Conduction Models of BGA Under An Expanded Boundary Condition Set", Proceedings of the ITHERM 2002, May 2002, San Diego, Ca, USA.
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Step 3: Generate a Mesh C. D. E. ii. iii. iv. v. vi. Input the estimated jc (1.4 C/W) and jb (6.75 C/W) values in the Rjc and Rjb fields respectively. Input a Junction power of 2.0 W. Click Done to finish.
Edit the Cabinet. In the Properties tab, you have the option to define the boundary condition (Wall type) for each side of the cabinet. Set the Wall type for Min x and Max x as Opening. Press Edit for the Min x side to open the Openings panel. In the Properties tab of the Openings panel, assign an X velocity of 1 m/s. Click Done to close the Openings panel. The Max x side opening should have the default settings (free opening).
viii. Click Done in the Cabinet panel to confirm changes. ix. You should see the openings on the min and max X sides of the cabinet.
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Chapter 19: Microelectronics Packages - Compact models a. b. Make sure Hexa unstructured is selected as the Mesh type and Normal is selected for Mesh parameters. Click Generate to create the mesh.
c. 2.
(optional) Create non-conformal assemblies around each package set to reduce the mesh count. As a start, use 3 mm slack values for all sides of each assembly. Resize the assemblies if required. With nonconformal assemblies, it is possible to reduce the number of elements in the mesh significantly. Display and compare the conformal and non-conformal meshes.
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Step 6: Calculate a Solution 2. Go to Solution settings Basic settings panel and click Reset. It is advisable to always click the reset button in the Basic settings panel before starting the solver. Set the number of iterations Adto 200 in the Basic settings panel and close the panel. Then go to Solution settings vanced settings to open the Advanced solver setup panel. Note that in the Advanced solver setup panel, under the Linear solver, the solver inputs for temperature have changed.
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2.
Go to Solve Run solution and enable Sequential solution of flow and energy equations.
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3.
Note the higher temperatures in the parts of the PCB under the PQFP packages.
Go to Report Network block values. The Message window lists all network block temperatures. Network junction temperatures can also be obtained from the overview report. The closeness of the PBGAs to each other is a cause for their overheating. How much is the problem due to the temperature of the air approaching these components? A picture of the thermal boundary layer over the PBGAs can be seen by taking XY cut plane of temperature contours over the PBGA blocks.
4.
What is the cause for the somewhat high temperatures of the TO-220 devices?
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Chapter 19: Microelectronics Packages - Compact models Are the heat spreaders too close? If so, the air flowing between the spreaders will overheat preventing further heat dissipation to the air. You can find out if this is the case by creating XZ cut planes of vectors and contours that cut across the spreader blocks.
5.
The highest temperatures are in the 400-PBGA blocks. Effective cooling solutions can be designed by understanding heat flow pathways. Generate a summary report of heat flow for the 400-PBGA blocks. By deactivating the button under Comb in the summary report panel, you can generate an itemization of heat flow through each of the sides of the object.
4.
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20.2. Prerequisites
The trainee should be familiar with: ANSYS Icepak modeling objects Basics of meshing Non-conformal meshing
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Chapter 20: Multi-Level Meshing improve mesh resolution at the same time using this technique along with the uniform mesh parameters option. Generate mesh without modifying the model. You will see a mesh count of about 650,000 cells.
Note
The mesh count may differ slightly on different machines.
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Step-by-Step Approach
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Generate a Mesh
Observe the decrease in element count. Display the mesh of the FLOW_GUIDE and the sheetmetal_hs_assy.1. Figure 20.3 (p. 318) shows the surface mesh on the flow_guide. Fine mesh resolution in some regions is necessary for a body fitted mesh. This can be clearly seen in the figure. In addition, it can be observed that the mesh resolution is coarser in regions where a fine resolution is not necessary to describe the geometry accurately. Figure 20.4 (p. 318) shows the mesh on and around the sheetmetal heatsink. It can be seen that the mesh resolution is fine in the fin region and coarser as we move away from the heatsink.
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Conclusion
20.10. Conclusion
Using multi-level meshing, we were able to improve the mesh resolution and instantly transition to coarser meshes thus reducing the overall mesh count. Hence, this approach significantly reduces run time while enhancing the accuracy of the simulation.
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21.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in ANSYS Icepak and that you have solved or read the tutorial "Finned Heat Sink" of this guide.
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Chapter 21: Characterizing a BGA-package by Utilizing ECAD Files a. b. Click on the packages object button ( ) in the objects toolbar.
In the Packages panel, click the Dimensions tab and select ASCII TCB from the Import ECAD file drop-down list.
c.
Note
block_1.tcb can be found in the installation directory at ICEPAK_ROOT/tutorials/BGA-package/block_1.tcb. d. e. f. g. Keep the numbers for the layers and vias and click Accept in the Board layer and via information panel. Click on the Die/Mold tab and assign a die Power of 0.5 W. Click Done. Click on the Cabinet in the object tree and click the Autoscale button located in the edit window in the lower right corner of the main menu.
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Note
Click the Scale to fit icon ( h. ) to refocus your model.
Right click on the package object in the object tree, choose Traces Color by trace to display the traces.
As can be seen in Figure 21.2 (p. 323), the wirebonds are lumped into polygonal plates by ANSYS Icepak. i. j. Change the cabinet zS to -1.2 mm. Create a PCB object and input the following in the Geometry tab: Plane xS yS zS k. X-Y -7.03 mm -7.03 mm -1.2 mm Specify by xE yE zE Start / end 7.03 mm 7.03 mm
In the Properties tab, set the substrate thickness as 0.8 mm, then enter the following Cu percentages for the layers:
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l.
Click on Update. Note that the thermal conductivity information (plane and normal) for the PCB is updated. Create a wall object and align it with the min-z side of the cabinet and Rename it as Bottom. Edit the wall object and insulate it by keeping the heat flux as zero in the Properties tab. Make a copy of the wall and translate it in the z direction by 2.95 mm and rename the new wall to Top. We would like to determine the heat transfer coefficient on the top surface with the wellknown correlation in the literature, (Incropera et. al 1). In order to do that, you can follow the procedure in Figure 21.4 (p. 325).
Frank Incropera and David DeWitt, Fundamentals of Heat and Mass Transfer, John Wiley & Sons, Inc., New York, 1981.
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Note
Ensure that Mesh type is Mesher-HD.
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4.
Click Close to close the panel once you have created the mesh.
Go to a. b.
Change the Number of iterations to 25 and the Convergence criteria for Energy to 1e-15. Click Accept to close the panel. Solution settings Advanced settings.
3.
Go to a. i. ii. b. c.
Input the following for Temperature in the Linear solver group box: Choose W from the Type drop-down list. Enter 1e-6 for both the Termination criterion and Residual reduction tolerance.
In the Precision drop-down list, select Double. Click Accept to save your settings and close the panel.
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b. c. d.
Select Show contours and click Parameters. Select This object from the Calculated drop-down list. Press Done in the Object face contours and Object face panels to close the panels and view the temperature contours.
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2.
Go to the Report Summary report and click on New twice. a. b. c. Choose Source_DIE1 under the package object for the first object and the Top wall for the second object. Keep the default selection of Temperature under Value for both. Press Write to create the Summary report.
Max die and max top wall temperatures are determined as 142.0 and 129.9C, respectively. Note that the top wall represents the case for the package. Therefore, junction-to-case resistance for this package is determined as: 328
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Step 8: Summary
=
Where
(211)
(212)
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22.2. Prerequisites
This tutorial assumes that you have reviewed Sample Session in the Icepak User's Guide and the tutorials "Finned Heat Sink" and "RF Amplifier" of this guide.
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The objective of this exercise is to illustrate the advantage of using the zero slack capability. The model will be constructed using the default metric unit system.
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2.
Note
You need to unzip the tcb file before you can import it. 3. In the Trace file panel, select BOARD_OUTLINE.tcb. Turn off the Resize Block option because the pcb was imported using an idf file, so the dimensions are already correct. This process may take a few minutes depending on the speed of your computer.
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Note
The Resize Block option is necessary when the board size is not known or an idf file is not available. 4. Once the import is completed, you can edit the layer information in the Board layer and via information panel. Enter the layer thickness as shown in the table below. Layer Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 Layer 6 Layer 7 5. Thickness (mm) 0.04 0.45364 0.062 0.467 0.055 0.442 0.045
By default, layers are lumped for each sub-grid, therefore, the Model layers separately option is off and will need to be enabled. a. b. c. Click Accept to close the Board layer and via information panel. Then click Edit next to Trace layers and vias in the Blocks panel to reopen the Board layer and via information panel. The Model layers separately option can now be enabled.
6. 7.
The via information is imported automatically, so keep the default settings. Click Accept to save your settings.
Note
You can view the traces in three different ways, i.e. Single color, Color by trace, or Color by layer. The meshing plates are placed at the location of the different layers; they are used to ensure the mesh resolution is high enough at the different layers.
8.
Note
Non-conformal assemblies are used to reduce mesh count in models and to improve mesh quality. 1. 334 Set the slack values for the heat sink assembly as shown in the figure below.
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Press Done to close the Per-object meshing parameters panel. Keep all other settings as default and click Generate.
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Chapter 22: Zero Slack with Non-Conformal Meshing 6. Take note of the mesh count and view a cut plane of the mesh from the Display tab.
Note
The package is not well resolved and it is divided between the heatsink and board assemblies. Moreover, mesh bleeding from the meshing plates extends beyond the board because of the slack values.
Note
Currently, zero slack assemblies are unable to participate in radiation when a surface coincides with the assembly interface. 1. Change the slack values for the heat sink assembly as shown in the figure below.
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2.
In addition, enable Mesh separately in the package and board assemblies (do not change any other values in these assemblies).
2.
Go to Problem setup Basic parameters and make sure the Flow regime is Turbulent and the turbulence model is Zero equation in the General setup tab. Also, give a small initial (global) X velocity of 1.5 m/s in Transient setup tab. Accept the changes made and exit this window.
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23.2. Prerequisites
This tutorial assumes that you have little experience with ANSYS Workbench and so each step will be explicitly described.
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Note
When ANSYS Workbench starts, the Toolbox and Project Schematic are displayed.
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Note
A green check mark in the Geometry cell indicates the geometry has been imported successfully. 2. Double-click the Geometry (A2) cell to open DesignModeler as you need to edit the geometry first before exporting into ANSYS Icepak. a. b. c. Keep the selection of Meter as the desired length unit and press OK. Click Generate to display the model. Edit the geometry in DesignModeler using the Electronics option in the Tools menu. Select Simplify and choose the appropriate simplification level and select bodies. i. ii. Select All objects for Selection Filter. Keep the Simplification Type as Level 2 and click Generate.
Refer to the Design Modeler documentation for more detailed information on using the Electronics options.
Note
The Electronics menu is shown only if the DesignModeler option Enable Electronics Options is turned on.
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Chapter 23: ANSYS Icepak - ANSYS Workbench IntegrationTutorial d. 3. 4. Close DesignModeler and return to ANSYS Workbench.
Drag and drop an Icepak template into the Project Schematic on top of the Geometry cell (A2) to transfer the geometry into ANSYS Icepak. Right click on the Setup cell (B2) and select Edit to launch ANSYS Icepak. a. The CAD model appears in the graphics display window and has been converted into ANSYS Icepak objects. Click the isometric toolbar icon ( b. ) to display the isometric view of the model.
In the object edit panel of each of the objects, rename the object (if necessary) in the Info tab and enter the specifications in Properties tab as shown in Table 23.1: Object Properties (p. 342).
Caution
It is recommended to use unique names for Icepak objects when importing from DesignModeler as objects may be erroneously skipped when re-importing the model or duplicated when refreshing the geometry.
Note
To open the object edit panel, perform a right mouse click on the object and select Edit. After editing the object, you can press Update to save the changes and click a different object in the Model tree to go to that object without closing the panel.
Note
Edit the Solid material by selecting a material in the drop down list. To create a (Custom) material, select Create material in the drop down list and click the Properties tab in the Materials panel and enter the specifications.
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Step 2: Build the Model c. Resize edit the properties of the default cabinet in the Cabinet panel. Model i. Cabinet
In the Cabinet panel, click the Geometry tab. Under Location, enter the following coordinates:
Edit the cabinet properties to specify Min x and Max x sides as openings. A. B. C. In the Properties tab of the Cabinet object panel, select Opening from the drop-down menu under Wall type for Min x and Max x. Select Edit to display the opening for the Max x object panel. In the Properties tab, specify the x velocity to be 2 m/s. Click Done in the Openings and Cabinet panels to apply the changes and close the panels.
d.
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Note
To add objects to an assembly, select one or more objects in the Model manager window and drag them into the desired assembly node.
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Step 3: Generate a Mesh 2. Go to the CPU_assembly object panel and click the Meshing tab. Enable the Mesh separately option and enter the following slack values. Click Done to close the panel.
Specify the overall mesh controls as shown in the Mesh control panel below. Model Generate mesh
Note
The Mesh units and Minimum gap values are in mm, and Set uniform mesh params is checked in the Global tab. Press Generate to create the mesh. You can check the mesh using the Display and Quality tabs in the Mesh control panel. Press Close when you are done.
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Go to Solution settings Basic settings and Solution settings Advanced settings in the Model manager window and verify that the following values are set for each variable: Basic settings No. of iterations = 100 Flow = 0.001 Energy = 1e-7 Advanced settings Pressure = 0.3 Momentum = 0.7
Note
You can click the save icon ( The Save As panel appears. 2. 3. Specify the name ice_wb for your project and click Save. ANSYS Workbench will close ANSYS Icepak to save the model, you will need to launch ANSYS Icepak again to continue. ) in the File commands toolbar.
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4.
Once the solution converges, click Done in the Solution residuals window to close it.
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Chapter 23: ANSYS Icepak - ANSYS Workbench IntegrationTutorial 1. After calculating a solution in ANSYS Icepak, a green check mark will be displayed in the Icepak Solution cell in the Project Schematic. The green check mark indicates that all data is up to date. Select Results under the Component Systems node in the Toolbox. Drag the Results cell on top of the Icepak Solution cell (B3) to transfer the data.
2. 3.
Double click the C2 Results cell to launch ANSYS CFD-Post. The model should appear in the display window. To generate contours, please do the following: a. b. Go to Insert Contour or click on the Contour button Contour 1 and click OK. In the Geometry tab under Details of Contour 1: i. ii. Keep the default selection of All Domains in the Domains drop-down list. Click on the ... button next to Locations to display the Locations Selector dialog box. Highlight all CPU, PCB and HEAT_SINK objects and click OK to close the panel. to create a contour. Retain the name
Note
You can select multiple objects by holding down either Shift or Ctrl and selecting the objects. iii. iv. 4. Select Temperature in the Variable drop-down list. Select Apply to display the contours.
To generate a 3D streamline, please do the following: a. b. Go to Insert Streamline or click on the Streamline button the name Streamline 1 and click OK. In the Geometry tab under Details of Streamline 1: i. ii. iii. iv. v. c. Keep the default selection of 3D Streamline in the Type drop-down list. Keep the default selection of All Domains in the Domains drop-down list. Select cabinet_default_side_maxx minx from the Start From drop-down list. Keep the default selection of Velocity in the Variable drop-down list. Keep all other defaults and click Apply to display the streamline. to create the streamline. Retain
You can also animate the streamline. To animate the streamline, go to Tools Animation or click on the animation button .
5.
When you are done examining the results, close ANSYS CFD-Post and return to ANSYS Workbench.
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Step 9: Summary
3. 4. 5. 6.
Right click on the Setup cell (D5) and click Update. Double click on the Model cell ( D4) to launch ANSYS Mechanical. Click on the Imported Body Temperature object. This object is found under the Imported Load (Solution) node. Under Details, ensure that the Scoping Method is Geometry Selection. Click the Box Select button
, hold down the Ctrl key and drag a box around the entire model to select it. Click on the cell to the right of Geometry and then click Apply. Nine bodies should be selected. 7. 8. Select All from the Icepak Body drop-down list. Click Solve.
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24.2. Prerequisites
Familiarity with the ANSYS Workbench interface Familiarity with the ANSYS Icepak interface
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Figure 24.2 Quick Reference - Mouse Button Mapping (default) in CFD Post:
To adjust or view the mouse mapping options, go to Edit Options, then Viewer Setup Mouse Mapping in ANSYS CFD-Post.
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Step 1: Create a New Project b. Drag an ANSYS Icepak component module from the Toolbox and drop it on the Project Schematic window as shown in Figure 24.4 (p. 353).
c.
Rename the ANSYS Icepak component module as Parametric Setup as shown in Figure 24.5 (p. 353). To rename the title, double click on the title Icepak or click the left mouse button on the down arrow ( ) and select the Rename option from the drop down list.
d.
As shown in Figure 24.6 (p. 354) and Figure 24.7 (p. 354), drag and drop a Results (ANSYS CFDPost) component module onto the Solution cell of the Parametric Setup to link the ANSYS Icepak analysis to ANSYS CFD-Post. Rename the Results component module to CFD Post.
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Figure 24.6 Linking the Results (ANSYS CFD-Post) Component to the ANSYS Icepak Component
e. 2.
Save the project using File/Save (name the project as ice-cfdpost) from the ANSYS Workbench interface. Right click the ANSYS Icepak Setup cell and import the packed ANSYS Icepak project file icecfdpost.tzr located in the project directory. The ANSYS Icepak interface will launch with the selected project loaded for modeling/analysis.
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Step 4: Postprocessing Using ANSYS CFD-Post 3. Go to Solve Run optimization. a. b. In the Design variables tab, review the parametric setup. In the Trials tab, note that two of the four trials will be considered for CFD analysis.
Create a Surface Group for the board and all the components.
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Chapter 24: Postprocessing Using ANSYS CFD-Post a. b. Go to Insert Location Surface Group. Name the group as BoardANDComponents.
c.
Go to the Details view located on the lower left hand side of the screen (see Figure 24.1 (p. 351)).
d.
As shown in Figure 24.10 (p. 356), hold down Shift and the left mouse button to select all but the last eight (cabinet*, fan and grille) surfaces from the list.
ii. e. 3. a.
Click OK to close the Location Selector panel and add the surfaces.
Click Apply in the Geometry tab to apply the settings. Go to Insert Location Surface Group and name the group CabinetSurfaces.
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Figure 24.11 Listing of Surface Groups under User Locations and Plots
b.
As before, open the Location Selector panel, but this time select only the cabinet surfaces, and press OK.
c.
In the Render tab, apply the settings as shown in Figure 24.13 (p. 358) and click Apply.
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d.
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e. 4.
Note that these newly create Surface Groups are listed under User Locations and Plots in the Outline tab. Change the Units for this postprocessing session. i. ii. iii. Go to Edit Options Units. Set the System to Custom. Set the unit for Temperature to C.
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iv. b. c.
Click Apply and then OK to set the units and close the panel.
Go to Insert Contour and create a new contour object named TemperatureContours. For the contour TemperatureContours, update the settings for the Geometry tab of the Details view as shown in Figure 24.16 (p. 361) and click Apply.
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d. e.
Go to the Render tab and deselect Show contour lines. Click Apply to create the contour.
Note
TemperatureContours is listed under User Locations and Plots. 5. Modify the display of the default legend view. a. b. Double click Default Legend View 1 listed under User Locations and Plots to access the corresponding Details view. Modify the settings in the Definitions and the Appearance tabs as shown in Figure 24.17 (p. 362) and click Apply.
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6.
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Step 4: Postprocessing Using ANSYS CFD-Post a. b. c. Deselect TemperatureContours in the User Locations and Plots node. Go to Insert Vector and create a new Vector object named HeatFluxVectors and click OK. Modify the Geometry tab of the Details view as shown in Figure 24.19 (p. 363) and click Apply.
7.
Plot Thermal Chokepoint, displaying regions of high heat flux on the Surface Group BoardANDComponents. a. Deselect HeatFluxVectors in the User Locations and Plots node.
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Chapter 24: Postprocessing Using ANSYS CFD-Post b. c. Go to Insert Contour and create a new Contour object named Chokepoint and click OK. Open the Location Selector panel and select only the ALPHA_MAIN_PCB surfaces. Press OK to close the Location Selector panel and add the surfaces.
d.
Modify the Geometry tab of the Details view as shown in Figure 24.22 (p. 365) and click Apply.
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8.
Plot Streamlines originating from the fan and colored by temperature. a. b. c. Deselect Chokepoint and select TemperatureContours in the User Locations and Plots node. Go to Insert Streamline and create a new Streamline object named StreamlinesFan and click OK to access the Details view panel. Modify the Geometry tab as shown in Figure 24.24 (p. 367) and click Apply.
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d.
Modify the Color tab as shown in Figure 24.25 (p. 367) and click Apply.
e.
Modify the Symbol tab as shown in Figure 24.26 (p. 368) and click Apply.
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9.
Create a Keyframe Animation of StreamlinesFan. a. b. Go to Tools Animation and select Keyframe Animation. Click the button to insert a new frame called KeyframeNo1 as shown in Figure 24.28 (p. 369).
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c.
Right click the background next to the model in the 3D viewer and select the View from +Y option under Predefined Camera.
d. e. f.
Add another keyframe called KeyframeNo2 to the Animation panel. Check the Animate Camera option on the Keyframe Animation panel (you may need to activate the display of the lower half of the Animation panel using the drop down arrow ). Similarly, update the display and add new frames as follows: i. View from -Z and add KeyframeNo3.
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Chapter 24: Postprocessing Using ANSYS CFD-Post ii. iii. g. h. i. Click View from +X and add KeyframeNo4. Isometric view (Y up) and add KeyframeNo5. to view the animation.
Click the Options button on the Animation panel to access the Animation Options panel. Set the Animation Speed to Slower from the drop-down menu by a factor of 20 and click OK.
j. k. l.
Replay the animation and note that the animation is less choppy compared to the original one. Close the Keyframe Animation panel. Deselect the TemperatureContours and StreamlinesFan objects under User Locations and Plots. Go to Insert Location Plane and create a plane named PlaneCut. Modify the Details for PlaneCut as shown in Figure 24.31 (p. 371) and click Apply.
10. Create a Plane object displaying temperature contours and velocity vectors. a. b.
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c. d.
Deactivate the display of the plane by deselecting PlaneCut and activate the contour display by selecting TemperatureContours under User Locations and Plots. Double click on TemperatureContours or right click Edit to access the Details view. Update the details as shown in Figure 24.32 (p. 371) and click Apply.
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e.
Go to the Details view for the PlaneCut (do not activate the display of the PlaneCut) and make the following modifications: i. ii. Switch Method to XY Plane and click Apply. Use the scroll bar to change the Z location for PlaneCut.
f.
The plane cut can also be traversed across the domain using the animation tools in CFD Post. i. ii. Go to Tools Animation and select Quick Animation (default) and highlight the PlaneCut object. Using the scroll bar, adjust the number of frames for the animation as shown in Figure 24.34 (p. 373) and click the button.
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iii. iv. v. g. h. i. j. k.
The animation can be viewed on the screen or can be written out to an animation file by checking the Save Movie option. Stop the animation by clicking the Close the Animation panel. button.
Deactivate the display of the contours by deselecting the TemperatureContours object under User Locations and Plots. Go to Insert Vector and create a vector object named VelVectors. Modify the Details for VelVectors to set the Location to PlaneCut and click Apply. As before, use the Details view for the PlaneCut to manually traverse the plane displaying the vectors across the domain. Deactivate the display of the vectors by deselecting Velvectors under User Locations and Plots. Go to Insert Location Isosurface and create an Isosurface name HotSpots. Modify the Details for HotSpots to create an isosurface for 27C (Variable: Temperature, Value: 27C). Similarly, modify the Details to create an isosurface for 3 m/s (Variable: Velocity, Value: 3 m/s). Deactivate the display of the isosurface by deselecting HotSpots under User Locations and Plots. Go to Insert Location Volume and create a Volume named IsoVolume. Modify the Details for IsoVolume as shown in Figure 24.35 (p. 374) and click Apply.
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c.
Deactivate the display of the volume by deselecting IsoVolume under User Locations and Plots.
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Step 4: Postprocessing Using ANSYS CFD-Post 13. Create a Chart of Temperature variation across a Line. a. b. Go to Insert Location Line and create a Line named ForChart. Modify the Details for ForChart as shown in Figure 24.37 (p. 375). and click Apply.
c. d. e.
Deactivate the display of the line by deselecting ForChart under User Locations and Plots. Go to Insert Chart to create a Chart named TemperatureVariation. Modify the Details for TemperatureVariation as follows: i. ii. iii. iv. v. General tab: Set the Type to XY. General tab: Set the Title to Temperature Variation along Z axis. Data Series tab: Set Location to ForChart. X Axis tab: Set Variable to Z. Y Axis tab: Set Variable to Temperature.
f.
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Note
The chart TemperatureVariation is added under the Report node of the Outline tree.
14. Create an Expression and Variable that can be used for postprocessing. a. Switch to the Expressions tab (located next to the Outline tab) and review the list of available expressions.
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Step 4: Postprocessing Using ANSYS CFD-Post i. Right click in the white space and click New to create a new expression named VelocityRatio.
ii. iii.
Click Ok to access the Details view for VelocityRatio. Right click the white space in the Definition tab to access the Functions, Expressions, Variables, Locations and Constants which will be used to create the expression VelocityRatio.
iv.
Create the expression as shown in Figure 24.39 (p. 377) and click Apply.
Note
Velocity is found under Variables, volumeAve()@ is found under Functions CFDPost, and default_fluid is found under Locations Other.
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Chapter 24: Postprocessing Using ANSYS CFD-Post b. Switch to the Variables tab and review the list of Derived, Geometric, Solution, and User Defined variables. i. Right click the white space and click New to create a new variable named VelRatio.
ii. iii.
Click Ok to access the details view for VelRatio. Select Expression for the Method and set VelRatio to correspond to the Expression VelocityRatio.
iv.
Note
VelRatio is listed under the User-Defined type of Variables. c. Contours, Isosurfaces, Vectors, Charts, etc. can now be plotted using this new variable.
c.
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Figure 24.40 Creation of New Results Component and Updated Project Schematic
d.
Double click the Results cell of Comparison Study to launch a new ANSYS CFD-Post session.
Note
As before, ANSYS CFD-Post automatically reads in the most recent solution set (trial 004). 2. As shown in Figure 24.41 (p. 380), go to File Load Results to load an additional solution set. Navigate to the ~ice-cfdpost_files/dp0/IPK/Icepak/IcepakProj folder to pick trial001.cfd.dat as the second solution set for the comparison study.
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3.
Set up the display of the two solution sets. a. Synchronize the camera and the visibility in the displayed views by turning on the corresponding features from the Shortcuts Toolbar (located above the models in 3D viewer displays).
b. c. 4.
Rotate, Zoom, or Pan one of the displays and confirm that the other display follows suit. Using the Shortcuts Toolbar, modify the display to a landscape view (switch from to )
As before, go to Insert Location Surface Group and create a Surface Group named BoardAndComponents.
Important
The Surface Group in this ANSYS CFD-Post session should include the board and component surfaces from BOTH solution sets. Use the Location Selector to select all but the last eight surfaces from each list. The easiest way to do this is to select all the objects from both groups using Shift and the left mouse button, then deselecting the cabinet objects from both groups using Ctrl and the left mouse button.
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5. 6.
Deselect BoardAndComponents from User Locations and Plots. As before, go to Insert Contour and create a new contour object named TemperatureContours and set its Locations to the BoardAndComponents Surface Group. Set Variable to Temperature and click Apply. Update the display of the Default Legend View (each display will need to be updated individually) as before.
7.
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8.
Go to Insert Streamline and create a Streamline object named StreamlinesFans and edit the Details as below: a. b. c. d. Geometry tab: Select fan1_minx from both solution sets for Start From and set # of Points to 50. Color tab: Set Mode to Variable and select Temperature for Variable. Symbol tab: Select Show Symbols and Show Streams. Set the Interval to 0.005 s. Click Apply.
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Step 6: Summary
e.
Perform a detailed comparison study using the various features (Isosurface, Plane, Animation etc.) discussed earlier in this tutorial.
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25.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in ANSYS Icepak and that you have solved or read the tutorial "Finned Heat Sink" of this guide. Some steps will not be shown explicitly.
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Note
You can rotate the cabinet around a central point using the left mouse button, or you can translate it to any point on the screen using the middle mouse button. You can zoom into and out from the cabinet using the right mouse button. To restore the cabinet to its default orientation, select Home position in the Orient menu.
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Chapter 25: High Density Datacenter Cooling 5. Go to Units in the Defaults node. a. b. Click Set all to Imperial. Click This project to apply the preferences to this project.
b. c.
Press Apply to resize the cabinet. Click the Isometric view button ( ) to show a scaled-to-fit isometric view of the cabinet.
Note
The walls of the cabinet are adiabatic and do not participate in radiation by default. Radiation will not be considered for this analysis. 2. Create the raised floor. a. Click the Create plates button ( ).
ANSYS Icepak creates a free rectangular plate in the x-y plane in the center of the cabinet. You need to change the orientation and size of the plate and its location within the cabinet. b. In the object geometry window: i. ii. iii. Set the Name to raisedfloor. Change the Plane to xz. Enter the following dimensions:
iv. 3. a. 388
Create the first CRAC unit. Go to Macros Datacenter components CRAC to open the CRAC panel.
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Step 3: Build the Model b. c. d. e. Enter the dimensions as shown below in Figure 25.4 (p. 389). Make sure the Flow direction is -Y. Select Mass flow rate and input a value of 15.9 lbm/s. Specify a Supply temperature of 55 F.
Note
Mass flow rate has units of lbm/s. f. Press Accept to create the CRAC unit.
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4.
Set the per-object meshing parameters for the fans crac_intake and crac_exhaust. a. b. Open the Mesh control panel by clicking the Generate mesh button ( In the Local tab, check Object params and press Edit. i. ii. iii. In the Per-object meshing parameters panel, Ctrl+left click crac_exhaust and crac_intake to select both objects. Check the Use per object parameters option. Check the X count and Z count options and specify a Requested value of 4 for both options. ).
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c. d. 5. a. b. c.
Click Done to close the Per-object meshing parameters panel. Click Close to close the Mesh control panel. Select all the CRAC objects by Shift+left clicking cracunit and then crac_exhaust in the Model manager window. Right click one of the selected objects and go to Create and then Group. In the Create group panel, enter CRACs in the Name for new group text field.
d. 6. a. b. c. d.
Press Done to create the new group. Expand the Groups node in the Model manager window. Right click CRACs and select Copy. In the Copy group panel, check Group name and enter CRACs. Check Translate and set the Z offset to 10 ft.
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e.
Press Apply and Done to copy the CRAC unit and close the panel.
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f. 7. a. b. c. d. e. f. g.
).
Create a row of server racks. Go to Macros Datacenter components Rack (Front to Rear). Input the dimensions as show below in Figure 25.9 (p. 394). Set the Flow direction to -X. Specify a Heat load of 3000 W. Specify a Volume flow of 450 cfm. Set the Number of racks to 11. Under Create additional racks along select +Z.
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h.
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Note
The volumetric flow rate input for the recirculation opening is converted by ANSYS Icepak to a mass flow rate input to the computational stage of the analysis. For this conversion, ANSYS Icepak uses the density specified for Air in the materials panel as shown below.
8.
Create a new group for the server racks. a. b. c. Select all the server rack objects by Shift + left clicking rack and then rack-opns.10 in the Model manager window. Right click one of the selected objects and go to Create and then Group. In the Create group panel, enter RACKs in the Name for new group text field.
d. 9. a. b. c. d. 396
Press Done to create the new group. Right click RACKs in the Groups node and select Copy. In the Copy group panel, check Group name and enter RACKs. Check Rotate and Translate in the Operations group box. Set the Axis to Y and the Angle to 180.
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f.
Press Apply and Done to copy the row of server racks and close the panel.
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10. Create a row of high density server racks. a. b. c. d. e. f. g. h. Go to Macros Datacenter components Rack (Front to Rear). Enter hdrack in the Name text field. Input the dimensions as show below in Figure 25.13 (p. 399). Set the Flow direction to -X. Specify a Heat load of 7000 W. Specify a Volume flow of 1000 cfm. Set the Number of racks to 11. Under Create additional racks along select +Z.
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i. a. b. c. d. a. b. c. d. e. f.
Press Accept to create the high density server racks. Select all the high density server rack objects by Shift+left clicking hdrack and then hdrackopns.10 in the Model manager window. Right click one of the selected objects and go to Create and then Group. In the Create group panel, enter HDRACKs in the Name for new group text field. Press Done to create the new group. Right click HDRACKs in the Groups node and select Copy. In the Copy group panel, check Group name and enter HDRACKs. Check Rotate and Translate in the Operations group box. Set the Axis to Y and the Angle to 180. Set the X offset to 7 ft. Press Apply and Done to copy the row of high density server racks and close the panel.
11. Create a new group for the high density server racks.
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Figure 25.14 Two Rows of High Density Server Racks in the Graphics Window
13. Create a row of perforated tiles. a. b. c. d. e. Go to Macros Datacenter components Tile. Set the Number of tiles to 11. Enter the dimensions as show below in Figure 25.15 (p. 401). Choose +Z. Enter 0.35 for Uniform under % Open area.
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f.
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14. Set the per-object meshing parameters for all the resistance objects. a. b. Open the Mesh control panel by clicking the Generate mesh button ( In the Local tab, press Edit next to the Object params option. i. ii. iii. iv. In the Per-object meshing parameters panel, Shift+left click tile and then tile.10 to select all the resistance objects. Check the Use per object parameters option. Check the X count and Z count options and specify a Requested value of 4 for both options. Check the Y count option and specify a Requested value of 3. ).
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c. d. a. b. c. d. a. b. c. d. e. f. g. h.
Click Done to close the Per-object meshing parameters panel. Click Close to close the Mesh control panel. Select all the tile objects by Shift+left clicking tile and then tile_open_bottom.10 in the Model manager window. Right click one of the selected objects and go to Create and then Group. In the Create group panel, enter TILEs in the Name for new group text field. Press Done to create the new group. Right click TILEs in the Groups node and select Copy. In the Copy group panel, check Group name and enter TILEs. Check Translate and set the X offset to 2 ft. Press Apply and Done to copy the row of perforated tiles and close the panel. Right click TILEs in the Groups node again and select Copy. In the Copy group panel, check Group name and enter TILEs. Check Translate and set the X offset to 14 ft. Press Apply and Done to copy both rows of perforated tiles and close the panel.
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17. Create the ceiling plenum. a. b. Click the Create plates button ( In the object geometry window: i. ii. iii. Set the Name to ceilingplenum. Change the Plane to xz. Enter the following dimensions: ).
iv.
18. Create a return grille. a. b. c. d. 404 Click the Create grille button ( ).
Double click the grille.1 object in the Model manager window to open the Grille panel. In the Info tab, enter ceiling-return under Name and enter CEILING-RETURN under Groups. In the Geometry tab, set the Plane to X-Z and enter the following dimensions:
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e. f. a. b. c. d. e. f. g. h. i.
In the Properties tab, set the Free area ratio to 0.5. Press Done to apply the settings and close the panel. Right click CEILING-RETURN in the Groups node and select Copy. Set the Number of copies to 2. In the Copy group panel, check Group name and enter CEILING-RETURN. Check Translate and set the Z offset to 9 ft. Press Apply and Done to copy the return grille and close the panel. Right click CEILING-RETURN in the Groups node again and select Copy. In the Copy group panel, check Group name and enter CEILING-RETURN. Check Translate and set the X offset to -14 ft. Press Apply and Done to copy the row of return grilles and close the panel.
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Chapter 25: High Density Datacenter Cooling 20. Create two more return grilles. a. b. c. d. Click the Create grille button ( ).
Double click the newly created object to open the Grille panel. In the Info tab, enter ceiling-return-crac1 under Name and select CEILING-RETURN from the Groups drop-down list. In the Geometry tab, set the Plane to X-Z and enter the following dimensions:
e. f. g. h. i. j. k.
In the Properties tab, set the Free area ratio to 0.5. Press Done to apply the settings and close the panel. Right click the vent ceiling-return-crac1 from the Model tree and select Copy. In the Copy group panel, check Group name and enter CEILING-RETURN. Check Translate and set the Z offset to 10 ft. Press Apply and Done to copy the return grille and close the panel. Right click ceiling-return-crac1.1 and Rename the object to ceiling-return-crac2.
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21. Set the per-object meshing parameters for the return grilles. a. b. Open the Mesh control panel by clicking the Generate mesh button ( In the Local tab, press Edit next to the Object params option. i. ii. iii. In the Per-object meshing parameters panel, Shift+left click ceiling-return and then ceiling-return.3 to select all the return grilles. Check the Use per object parameters option. Check the X count and Z count options and specify a Requested value of 4 for both options. ).
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c. d. a. b. c. d. e.
Click Done to close the Per-object meshing parameters panel. Click Close to close the Mesh control panel. Go to Macros Datacenter components PDU to open the PDU panel. Enter the dimensions as shown below in Figure 25.22 (p. 409). Set the PDU flow direction to +Y. Set the Heat output to 3600 W. Set the Percent open area on top and the Percent open area on bottom to 0.25.
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f.
23. Set the per-object meshing parameters for the grilles pdu_vent_in and pdu_vent_out. a. b. Open the Mesh control panel by clicking the Generate mesh button ( In the Local tab, check Object params and press Edit. i. ii. iii. c. d. a. b. c. d. In the Per-object meshing parameters panel, Ctrl+left click pdu_vent_in and pdu_vent_out to select both objects. Check the Use per object parameters option. Check the X count and Z count options and specify a Requested value of 4 for both options. ).
Click Done to close the Per-object meshing parameters panel. Click Close to close the Mesh control panel. Select all the PDU objects by Shift+left clicking pdu_unit and then pdu_part4 in the Model manager window. Right click one of the selected objects and go to Create and then Group. In the Create group panel, enter PDUs in the Name for new group text field. Press Done to create the new group.
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Chapter 25: High Density Datacenter Cooling a. b. c. d. Right click PDUs in the Groups node and select Copy. In the Copy group panel, check Group name and enter PDUs. Check Translate and set the X offset to 14 ft and the Z offset to 28 ft. Press Apply and Done to copy the PDU and close the panel.
e.
).
26. Create blockages. a. b. Click the Create blocks button ( In the object geometry window: i. ii. iii. Set the Name to piping and the Group to BLOCKAGE. Set the Type to Hollow. Enter the following dimensions: ).
iv.
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Step 3: Build the Model c. d. Click the Create blocks button ( In the object geometry window: i. ii. iii. Set the Name to blockage and the Group to BLOCKAGE. Set the Type to Hollow. Enter the following dimensions: ).
iv.
27. Create columns. a. b. Click the Create blocks button ( In the object geometry window: i. ii. iii. Set the Name to column1 and the Group to COLUMNS. Set the Type to Hollow. Enter the following dimensions: ).
iv. c. d.
Click the Create blocks button ( In the object geometry window: i. ii. iii.
Set the Name to column2 and the Group to COLUMNS. Set the Type to Hollow. Enter the following dimensions:
iv.
28. Create cabletrays. a. b. Click the Create blocks button ( In the object geometry window: i. ii. Set the Name to cabletray1 and the Group to CABLETRAYS. Set the Type to Hollow.
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).
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Chapter 25: High Density Datacenter Cooling iii. Enter the following dimensions:
Press Apply to resize and rename the object. Right click CABLETRAYS in the Groups node and select Copy. In the Copy group panel, check Group name and enter CABLETRAYS. Check Translate and set the X offset to 6 ft. Press Apply and Done to copy the cabletray and close the panel. Right click CABLETRAYS in the Groups node again and select Copy. In the Copy group panel, check Group name and enter CABLETRAYS.
vii. Check Translate and set the X offset to 14 ft. viii. Press Apply and Done to copy the cabletrays and close the panel.
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Note
The units for the Minimum gap values are in inches. 3. 4. 5. Click Generate. Use the Display and Quality tabs to view the mesh and check the mesh quality. Click Close to close the panel once you have finished viewing the mesh.
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e. 2.
Press Accept to apply the settings and close the panel. Basic settings.
Go to a. b.
Change the Number of iterations to 1000 and the Convergence criteria for Energy to 1e-6. Click Accept to apply the settings and close the panel. Solution settings Advanced settings.
3.
Go to a. b. c.
Set the Discretization scheme for Pressure as Body Force Weighted. Set the Under-relaxation to 0.2 for Momentum and to 0.1 for Body forces. Click Accept to apply the settings and close the panel.
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Note
The actual values of the residuals may differ slightly on different machines, so your plots may not look exactly the same as Figure 25.27 (p. 416) and Figure 25.28 (p. 417).
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4.
Click Done in the Solution residuals and Temperature Point monitors windows to close them.
Enter surface-temp-contours in the Name field. In the Object drop-down list, expand the Groups node and Ctrl+left click CRACs, HDRACKs, PDUs, and RACKs, and click Accept.
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d. e.
Check Show contours and click Create. Click Done to close the panel.
2.
Display animated contours of temperature on plane cuts in all 3 coordinate planes. a. Right click surface-temp-contours under the Post-processing node in the Model manager window, and make the object face inactive by unchecking Active in the context menu. Click the Plane cut button ( ).
b. c.
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Step 9: Examine the Results d. Check Show contours and click Create to view a plane cut of the temperature contours.
e. f.
Check the Loop mode option and click Animate to display a loop of the plane cut traversing from the min z to the max z side of the datacenter. Click Interrupt on the progress bar to return to the Plane cut panel.
g. h. 3. a.
Repeat the above procedure for plane cuts in the Y-Z and X-Z planes by changing the Set position to X plane through center and Y plane through center respectively. Click Done to close the panel. Right click plane-temp-contours in the Model manager window and make the plane cut inactive by unchecking Active in the context menu. Click the Isosurface button ( Enter 90 in the Value field. Check Show contours and click Create to view the isosurface of 90F. ).
b. c. d. e.
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f.
To view an a loop of isosurfaces from 90F to 80F: i. ii. iii. In the Animation group box, enter 90 for Start, 80 for End, and 10 for Steps. Check the Loop mode option and click Animate. Click Interrupt on the progress bar to return to the Isosurface panel.
g. 4. a.
Click Done to close the panel. Right click iso-temp in the Model manager window and make the isosurface inactive by unchecking Active in the context menu. Click the Object face button ( ).
b. c. d.
Enter airflow in the Name field. In the Object drop-down list, expand the Groups node and Ctrl+left click CEILING-RETURN, HDRACKs, PDUs, RACKs, and TILEs, and click Accept.
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e. f. g. h. i.
Check Show particle traces and click Parameters. Set the Display options to Mesh points. Set the End time under Particle options to 5. Check Loop mode under Animation and set the Steps to 50. Click Apply to display the airflow patterns.
Note
ANSYS Icepak will take a few moments to generate the airflow patterns.
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j. k. l. n. 5.
Click Animate to visualize the airflow patterns in a transient manner. View the animated airflow patterns from various angles from the Orient menu. Press Interrupt to stop the animation. Right click airflow in the Model manager window and make the particle traces inactive by unchecking Active in the context menu. Go to Report Summary report to open the Define summary report panel. Click New to get a new field to define the Summary report. In the Objects drop-down list, expand the Groups node and select TILEs, and click Accept. Select Volume flow from the Value drop-down list and deselect Comb.
m. Click Done in the Object face particles and Object face panels to close them.
Report the volumetric flow rate distribution at the perforated floor tiles. a. b. c. d.
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e.
f. g. 6.
Click Done to close the Report summary data panel. Click Close to close the Define summary report panel. ) the project and Close ANSYS Icepak.
Save (
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25.13. Step 10: Additional Exercise: Visualize and analyze the results in ANSYS CFD-Post
In addition to using the postprocessing tools contained within ANSYS Icepak, you can also postprocess using the advanced tools in ANSYS CFD-Post through ANSYS Workbench. See "Postprocessing Using ANSYS CFD-Post" for details on how to use the features in ANSYS CFD-Post.
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26.2. Prerequisites
Familiarity with the ANSYS Workbench interface Familiarity with the ANSYS Icepak interface
Figure 26.1 Comparison of the Geometry in ANSYS DesignModeler and ANSYS Icepak
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Chapter 26: Design Modeler - Electronics b. c. Drag a Geometry (ANSYS DesignModeler) component module from the Toolbox and drop it on the Project Schematic window as shown in Figure 26.2 (p. 426). Rename the Geometry component module to STEP Import and DME to Icepak Translation. To rename the title, double click on the title Geometry or click the left mouse button on the down arrow ( ) and select the Rename option from the drop down list.
d. e.
Save the project (name the project as DME). Double click cell A2 to open ANSYS DesignModeler.
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2. 3.
Go to File Import External Geometry File and select DME.stp and press Open. Click to create the model.
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4.
Note
The Electronics drop down menu in the toolbar contains several options:
You can also access the You can also access the
option from the Create menu. and Electronics options from the Tools menu.
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Note
We will not have to make modifications to export these bodies into ANSYS Icepak. b. Go to Electronics Show CAD Bodies. Only bodies with complex geometries not recognized as ANSYS Icepak will be visible.
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Note
These are the bodies we will have to modify in order to export these bodies into ANSYS Icepak. c. 3. a. b. c. d. e. Go to Electronics Revert View to return to the previous display. In the Tree Outline, right click Housing and select Hide All Other Bodies. Select from the Shortcuts toolbar. In the Details view, set the Slice name to FinsSlice1. Select Slice by Surface for Slice Type. Click on the field to the right of Target Face and select the one of faces at the base of the fins, as shown in Figure 26.7 (p. 431) and click Apply.
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Note
If you cannot select the face, try pressing the Model Faces selection filter ( ). f. g. h. 4. a. Make sure Slice Targets is set to Selected Bodies. Click the field to the right of Bodies and select the Housing body. Click Apply and then .
Likewise, create a Slice for the other set of fins. Use the procedure described above on the other set of fins and name the second Slice FinsSlice2.
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Note
Make sure that the Bodies selection is the larger section of the housing containing the fins.
5.
Note
The Parts will become Assemblies in ANSYS Icepak. a. b. Press +Y on the Triad (the axes) to get a clear view of the fins. Select Box Select from the Shortcuts toolbar.
c. d.
Select the Bodies selection filter ( ). Drag the bounding box around one set of fins, and rotate the model to make sure that all the fins are selected as shown in Figure 26.9 (p. 433) (you should have 13 bodies selected).
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e. f. g. 6. a. b. c.
Right click anywhere in the Model View and select Form New Part. In the Details view, set the Part name to Fins1 and press enter on the keyboard. Repeat steps a to f for the other set of fins, except name the part Fins2. Select from the Shortcuts toolbar.
Create a Housing slice. In the Details view, set the Slice name to HousingSlice1. Select Single Select from the Shortcuts toolbar.
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Chapter 26: Design Modeler - Electronics d. Click the field to the right of Target Face and select the inner face of bottom of the Housing as shown in Figure 26.10 (p. 434) and press Apply.
e. f.
Make sure Slice Targets is set to Selected Bodies. Click the field to the right of Bodies and select the Housing object in between the fins.
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g. 7. a. b. c.
Create another Housing slice. from the Shortcuts toolbar. In the Details view, set the Slice name to HousingSlice2. Select the inner face of the top of the Housing as shown in Figure 26.12 (p. 436) and press Apply.
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d. e. f. 8. a. b. c. d. e.
Click the field to the right of Bodies and select the top part of the Housing object in between the fins. Click Apply and then .
You should have ten Housing objects outside of the Fins parts in the Tree Outline. Show all bodies again by right clicking one of the objects in the Tree Outline and clicking Show All Bodies Go to the +Y view. Go to Electronics Opening. In the Details view, set the Opening name to FanOpenings. Click the field to the right of Faces and select the face as shown in Figure 26.13 (p. 437) and press Apply and .
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9.
Create Openings for the back panel. a. b. c. d. Go to the -Y view. Go to Electronics Opening. In the Details view, set the Opening name to BackOpenings. Click the field to the right of Faces and select the face as shown in Figure 26.14 (p. 437) and press Apply and .
10. Create a Fan. a. Right click the Fan body in the Tree Outline and select Hide All Other Bodies.
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Note
If you cannot view the object correctly, press Zoom to Fit ( ). b. c. d. e. Go to Electronics Fan. In the Details view, set the Fan name to FanGeom. Click the field to the right of Body To Extract Fan Data, select the entire fan body and press Apply. Click the field to the right of Hub/Casing Faces and select the faces as shown in Figure 26.15 (p. 438).
Note
You can select multiple faces by holding down Ctrl and left clicking the objects. f. Click Apply and .
Note
Although it may seem like there was no change, this step creates a fan object in ANSYS Icepak. To confirm this, you can go to Electronics Show Ice Bodies and check if the fan is present.
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Step 4: Edit the Model for ANSYS Icepak g. Add the fan to the Front-Panel part. i. ii. iii. a. b. c. d. e. In the Tree Outline, select the Front-Panel part and then Ctrl and left click the Fan object. Right click the Fan object and select Form New Part. In the Details view, rename the Front-Panel Part to Front-Panel-Fan.
11. Perform a Simplify operation on the Housing. Show all bodies again by right clicking one of the objects in the Tree Outline and clicking Show All Bodies Go to Electronics Simplify. In the Details view, set the Simplify name to HousingFrontBack. In the field to the right of Simplification Type, select Level 1. Click the field to the right of Select Bodies and select the front and the rear panels of the Housing as shown in Figure 26.16 (p. 439).
f. a. b. c. d. e.
12. Perform a Simplify operation on the PWB and the T0220 objects. Select all the Housing, Fin, Panel, Opening, and Fan objects from the bottom of the Tree Outline by holding down Shift and using the left mouse button. Right click one of the selected objects and select Hide Body to view just the internal components. Go to Electronics Simplify. In the Details view, set the Simplify name to PWB_T0220. In the field to the right of Simplification Type, select Level 1.
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Chapter 26: Design Modeler - Electronics f. Click the field to the right of Select Bodies and select the PWB and all the HS_AF0 and T0220_Case objects.
Note
Because they are simple bodies that are already recognized as ANSYS Icepak objects, do not select the LEAD_1_AF0 or the HS_AF0 objects. i. ii. iii. Go to the +Z view. Make sure the Select Mode is Single Select. Hold down Ctrl and select the objects as shown in Figure 26.17 (p. 440).
iv. g. a.
13. Add all the package objects to the Parts. Change the Selection Mode to Box Select and make sure the selection filter is set to Bodies.
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Step 4: Edit the Model for ANSYS Icepak b. Select a package object as shown in Figure 26.18 (p. 441). There should be 6 bodies selected.
c. d. e.
Right click the model and select Form New Part. All the bodies will be added to the part. Name the part T0220_Case1. Repeat steps a to e for the rest of the packages, except naming the parts T0220_Case2, T0220_Case3, etc. Go to Electronics Simplify. In the Details view, set the Simplify name to CoilAssembly. In the field to the right of Simplification Type, select Level 1. Click the field to the right of Select Bodies and select the bodies as shown in Figure 26.19 (p. 442). There should be 4 bodies selected.
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e. a. b. c. d. a. b. c. d.
15. Add the rest of the Coil bodies to the part. Make sure the selection filter is set to Bodies. Make the same selection as in the simplify operation. Notice that there are now 8 bodies instead of 4. Right click the model and select Form New Part. In the Details view, set the Part name to CoilAssembly2. Go to Electronics Simplify. In the Details view, set the Simplify name to Capacitors. In the field to the right of Simplification Type, select Level 3. Click the field to the right of Select Bodies and select the bodies as shown in Figure 26.20 (p. 443). There should be 3 bodies.
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e. f. g. a. b. c. d. a. b.
17. Form a part for the Capacitors. Make sure the selection filter is set to Bodies. Make the same selection as the simplify operation. There should still be 3 selected bodies. Right click the model and select Form New Part. In the Details view, set the Part name to Capacitors. Make sure the selection filter is set to Bodies. Follow the same steps as before to create a part called BGAHS for the Heat Sink and Components for the Components:
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19. Right click a body in the Tree Outline and select Show All Bodies. Your model should look like Figure 26.22 (p. 444) and your Tree Outline should look like Figure 26.23 (p. 445).
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Note
Some of your parts and bodies may be in a different order than what is shown in Figure 26.23 (p. 445). 20. Check if all the bodies have been converted to ANSYS Icepak objects. a. b. Go to Electronics Show CAD Bodies. Confirm that the view contains no bodies. This means all the bodies have been recognized by ANSYS Icepak.
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3. 4. 5.
Double click the Setup cell (B2) to open the model in ANSYS Icepak. In the model manager window, right click the Model node and select Expand all to view the geometry inside the assemblies. Notice that the bodies have been successfully transferred into ANSYS Icepak.
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Step 6: Summary
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Index
B
BGA-package, 157, 321
J
joule heating, 283
L
loss coefficient, 143 loss coefficient vs Re, 155
C
CAD geometry, 245 import, 247 CFD Post, 351 CFD Post in Workbench, 351 cold-plate, 97, 101
M
mesh exercise, 133 microelectronics, 295 modeling model layers separately, 281 radiation, 196 monitor point, 308 mouse conventions, 2 multi-level meshing, 311, 314
D
Datacenter cooling high density, 385 Design Modeler electronics, 425 Dimensions tab, 322
N
non-conformal assembly, 101 mesh, 121, 127, 129 nested, 113
E
Edit object panel, 7 Electronics Design Modeler, 425
O
object parameters, 221 obtaining support, 2 optimization run, 181 orthotropic material properties, 110
F
finned heat sink, 3, 17 Functions compound, 178 objective, 178 primary, 178
P
param value, 175 parameterization, 71 parametric runs, 162 parametric trials, 147 multiple trials, 84
H
heat pipe, 107, 113 heat sink, 49 finned, 3, 17 inline or staggered, 157 heat transfer coefficient, 325 help obtaining support, 2 hex-dominant, 257
R
radiation model discrete ordinates, 185, 197 ray tracing, 197 rf amplifier, 37, 53
I
Icepak in Workbench, 339 import CAD file, 247 IDF, 235, 268 tcb file, 322 trace layer, 271, 333
S
search fan library, 50 summary report, 126 support obtaining help, 2
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Index
T
Thermal Resistance, 173 trace heating, 283 trace layer, 267 import, 271, 333 transient simulation, 201 typographical conventions, 1
W
Workbench Icepak, 339
Z
zero slack, 136, 331, 336 zoom-in modeling, 217, 224
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