Manifold configurations for uniform flow via topology optimisation and flow visualisation

The current study proposes compact and adaptable manifold configurations for achieving uniform flow distribution with minimal pressure drop, for electronics cooling and many other industrial applications. Two-dimensional topology optimisation generates new manifold configurations, referred to as mini-baffle and baffle. Both configurations use proportionately sized obstructions to regulate flow distribution and achieve excellent uniformity. Elliptical pins, with parametrically optimised diameters, are adopted to represent the mini-baffle configuration and tested using a three-dimensional model and flow visualisation experiments. Computational results show that introducing these pins reduces the variation of normalised channel flow rates from 19% to 1% with only an 8% increase in the pressure drop, at a Reynolds number of 200. Experimental results support this, with variation reduced from 20% to 7%, the slight increase due to manufacturing limitations. Results also show the influence of vortices, formed at the inlet, on flow distribution. A test section printed in a single piece demonstrates a streamlined and cost-effective manufacturing method for milli-fluidic devices. Coupling topology with parameter optimisation provides a method for accurately extracting discrete optimised geometries for physical manufacturing.