CFD of roughness effects on laminar heat transfer applied to additive manufactured minichannels

Additive manufacturing has received significant interest in the fabrication of functional channels for heat transfer; however, the inherent rough surface finish of the additively manufactured channels can influence thermal performance. This study investigates the impact of roughness on the thermo-fluid characteristics of laminar forced convection in rough minichannels. A numerical model was developed to create 3D Gaussian roughness with specified root-mean-square height. The finite volume method was used to solve the conjugate heat transfer of developed laminar flow in square minichannels. For Reynolds numbers ranging from 200 to 1600, the simulation results indicated enhanced heat transfer and increased flow resistance as Reynolds number increases, compared to a smooth minichannel, where effects on heat transfer and flow friction were negligible. For channels with relative roughness (root-mean-square height to channel hydraulic diameter) of 0.0068, 0.0113, and 0.0167, increasing the Reynolds number led to increased friction factor by 1.56, 1.71, and 2.91%, while the Nusselt number was enhanced up to 0.03%, 32.74%, and 46.05%, respectively. Heat transfer reduced in roughness valleys due to the presence of local low-velocity fluid in these regions; however, recirculation regions can occur in deep valleys of high roughness, increasing heat transfer and flow friction. Heat transfer was enhanced over roughness peaks due to flow impingement on the windward face of roughness as well as intensified energy transfer to the channel wall from roughness. Moreover, surfaces with higher roughness have a greater number of high peaks providing a thermal-flow path of a larger area and a thermal conductivity greater than that of the fluid.