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Numerical and experimental validation of Taguchi-optimized star-core fin inserts for enhanced thermal hydraulic
Zeki Ali Al-Saadi1, Adnan Ibrahim2, Sharul Sham Dol3
1Solar Energy Research Institute, Universiti Kebangsaan Malaysia, Bangi, 43600, Selangor, Malaysia.
Scientific Reports
|December 12, 2025
Summary
A novel star-core fin insert significantly enhances heat transfer in compact thermal systems. This passive design improves the thermal-hydraulic performance factor by 75% with optimized geometry.
Area of Science:
- Mechanical Engineering
- Thermodynamics
- Fluid Dynamics
Background:
- Compact thermal systems face challenges in heat transfer enhancement.
- Internal geometry is crucial for disrupting flow and increasing surface exposure.
- Improving convective efficiency is key for thermal system performance.
Purpose of the Study:
- To develop and optimize a novel star-core fin insert for enhanced heat transfer.
- To improve the thermal-hydraulic performance factor (THPF) in compact thermal systems.
- To identify optimal geometric parameters for the fin insert design.
Main Methods:
- Utilized a hybrid optimization approach combining the Taguchi method and Computational Fluid Dynamics (CFD) simulations.
- Systematically evaluated five geometric parameters: fin diameter, number of fin edges, number of fins per rod, fin thickness, and angular offset.
- Validated numerical predictions through experimental testing of a physical prototype.
Main Results:
- The optimal star-core fin insert configuration (Case 31) achieved a THPF of 1.75, a 75% improvement over a smooth pipe.
- Key optimal parameters included a fin diameter of 14.5 mm, five edges, four fins per rod, 3 mm thickness, and 0° angular offset.
- Experimental results showed strong agreement with CFD predictions (95.5% correlation, 4.5% RMSE).
Conclusions:
- The integrated optimization framework is reliable and effective for enhancing heat transfer.
- The star-core fin insert improves heat transfer performance while maintaining acceptable pressure losses.
- This passive design offers a scalable and energy-efficient solution for next-generation compact heat exchangers.
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