Vdocuments - MX - Ansys Icepak Tutorials PDF

ANSYS Icepak Tutorials
ANSYS, Inc. Release 14.0

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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
3.8. 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
4.6. Step 3: Creating Separately Meshed Assemblies ............................................................................... 83
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
4.13. Step 10: Examine the Results ......................................................................................................... 90
4.14. Step 11: Reports ............................................................................................................................ 93
4.15. Step 12: Summary ......................................................................................................................... 93
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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
5.6. 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
5.10. Step 7: Calculate a Solution .......................................................................................................... 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
6.12. Step 9: Summary ......................................................................................................................... 119
7. Non-Conformal Mesh .......................................................................................................................... 121
7.1. Introduction ................................................................................................................................. 121
7.2. Prerequisites ................................................................................................................................. 121
7.6. Step 3: Generate a Conformal Mesh ............................................................................................... 124
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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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
9.6. Step 3: Define Parameters and Trials ............................................................................................... 146
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
10.11. Step 8: Define Monitor Points ..................................................................................................... 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
11.6. Step 3: Define Design Variables .................................................................................................... 175
11.9. Step 6: Save the Model ................................................................................................................ 178
11.10. Step 7: Define Primary, Compound, and Objective Functions ....................................................... 178
11.13. Step 10: Summary ..................................................................................................................... 182
11.14. Step 11: Additional Exercise ....................................................................................................... 182
12. Radiation Modeling .......................................................................................................................... 185
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12.1. Introduction ............................................................................................................................... 185

12.2. Prerequisites ............................................................................................................................... 185
12.8. Step 5: Solving the Model Without Radiation ................................................................................ 193
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
12.15. Step 12: Summary ..................................................................................................................... 200
13. Transient Simulation ......................................................................................................................... 201
13.1. Introduction ............................................................................................................................... 201
13.2. Prerequisites ............................................................................................................................... 201
13.10. Step 8: Generate a Summary Report ........................................................................................... 207
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
14.11. 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
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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
16.4. Step 1: Creating a New Project ..................................................................................................... 246
16.11. Step 8: Summary ....................................................................................................................... 265
17. Trace Layer Import for Printed Circuit Boards ................................................................................... 267
17.1. Introduction ............................................................................................................................... 267
17.2. Prerequisites ............................................................................................................................... 267
17.6. Conduction Only Model (PCB Without the Components) .............................................................. 276
17.8. Step 2: Set Physical and Numerical Values .................................................................................... 277
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
17.17. 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
18.11. Step 8: Summary ....................................................................................................................... 294
19. Microelectronics Packages - Compact models .................................................................................. 295
19.1. Introduction ............................................................................................................................... 295
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19.2. Prerequisites ............................................................................................................................... 295

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
21.11. Step 8: Summary ....................................................................................................................... 329
22. Zero Slack with Non-Conformal Meshing ......................................................................................... 331
22.1. Introduction ............................................................................................................................... 331
22.2. Prerequisites ............................................................................................................................... 331
22.5. Step 2: Default Units .................................................................................................................... 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
22.16. Step 13: Summary ..................................................................................................................... 338
23. ANSYS Icepak - ANSYS Workbench IntegrationTutorial ................................................................... 339
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23.1. Introduction ............................................................................................................................... 339

23.2. Prerequisites ............................................................................................................................... 339
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
24.5. Step 2: Parametric Trials and Solver Settings ................................................................................. 354
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
25.5. Step 2: Set Preferences ................................................................................................................ 387
25.8. Step 5: Create Monitor Points ....................................................................................................... 413
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
26.6. 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
1.1. What's In This Manual
This manual contains tutorials that teach you how to use ANSYS Icepak to solve different types of
problems. In each tutorial, features related to problem setup and postprocessing are demonstrated.
The tutorial "Finned Heat Sink" provides detailed instructions designed to introduce the beginner to
ANSYS Icepak. This tutorial provides explicit instructions for all steps in the problem setup, solution,
and postprocessing. The remaining tutorials assume that you have read or solved the tutorial "Finned
Heat Sink", or that you are already familiar with ANSYS Icepak and its interface. In these tutorials, some
steps will not be shown explicitly. The input files are available in the installation area and available for
download on the ANSYS Customer Portal.
1.2. How To Use This Manual

Depending on your familiarity with computational fluid dynamics and ANSYS Icepak, you can use this
tutorial guide in a variety of ways:
1.2.1. For the Beginner
1.2.2. For the Experienced User
1.2.1. For the Beginner

If you are a beginning user of ANSYS Icepak, you should first read and solve the tutorial "Finned Heat
Sink", in order to familiarize yourself with the interface and with basic setup and solution procedures.
You may then want to try a tutorial that demonstrates features that you are going to use in your applic-
ation. For example, if you are planning to solve a problem involving radiation, you should look at the
tutorial "Radiation Modeling".
You may want to refer to other tutorials for instructions on using specific features, such as grouping
objects, even if the problem solved in the tutorial is not of particular interest to you.
1.2.2. For the Experienced User

If you are an experienced ANSYS Icepak user, you can read and/or solve the tutorial(s) that demonstrate
features that you are going to use in your application. For example, if you are planning to solve a
problem involving radiation, you should look at the tutorial "Radiation Modeling".
You may want to refer to other tutorials for instructions on using specific features, such as grouping
objects, even if the problem solved in the tutorial is not of particular interest to you.
1.3. Typographical Conventions Used In This Manual

Several typographical conventions are used in this manual's text to facilitate your learning process.
• Different type styles are used to indicate graphical user interface menu items and text inputs that you
enter (e.g., Open project panel, enter the name projectname).
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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.
For example, indicates that you will need to click on this button (in this case, to open the Walls
panel) in the toolbar.
1.4. Mouse Conventions Used In This Manual

The default mouse buttons used to manipulate your model in the graphics window are described in
Manipulating Graphics With the Mouse in the Icepak User's Guide. Although you can change the mouse
controls in ANSYS Icepak to suit your preferences, this manual assumes that you are using the default
settings for the mouse controls. If you change the default mouse controls, you will need to use the
mouse buttons you have specified instead of the mouse buttons that the manual tells you to use.
1.5. When To Call Your ANSYS Icepak Support Engineer

The ANSYS Icepak support engineers can help you to plan your modeling projects and to overcome
any difficulties you encounter while using ANSYS Icepak. If you encounter difficulties we invite you to
call your support engineer for assistance. However, there are a few things that we encourage you to
do before calling:
1. Read the section(s) of the manual containing information on the options you are trying to use.
2. Recall the exact steps you were following that led up to and caused the problem.
3. Write down the exact error message that appeared, if any.
4. For particularly difficult problems, package up the project in which the problem occurred (see Packing
and Unpacking Model Files in the Icepak User's Guide for instructions) and send it to your support en-
gineer. This is the best source that we can use to reproduce the problem and thereby help to identify
the cause.
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Chapter 2: Finned Heat Sink
2.1. Introduction
This tutorial demonstrates how to model a finned heat sink using ANSYS Icepak.
In this tutorial you will learn how to:
• Create a new project.

• Create blocks, openings, fans, sources, and plates.
• Include effects of turbulence in the simulation.
• Calculate a solution.
• Examine contours and vectors on object faces and on cross-sections of the model.
2.2. Prerequisites
This tutorial assumes that you have little to no experience with ANSYS Icepak and so each step will be
explicitly described.
2.3. Problem Description

The cabinet contains an array of five high-power devices, a backing plate, ten fins, three fans, and a
free opening, as shown in Figure 2.1 (p. 4). The fins and backing plate are constructed of extruded
aluminum. Each fan has a total volume flow rate of 18 cfm and each source dissipates power at the rate
of 33 W. According to the design objective, the base of the devices should not exceed 65°C when the
fins are swept with air at an ambient temperature of 20°C.
Figure 2.1 Problem Specification
2.4. Step 1: Create a New Project

1. Start ANSYS Icepak, as described in Starting ANSYS Icepak in the Icepak User's Guide.
When ANSYS Icepak starts, the Welcome to Icepak panel opens automatically.
2. Click New in the Welcome to Icepak panel to start a new ANSYS Icepak project.
The New project panel appears.
Step 2: Build the Model
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.
2.5. Step 2: Build the Model

To build the model, you will first resize the cabinet to its proper size. Then you will create the backing
plate and opening, followed by the elements that will be duplicated (i.e., the fans, fins, and devices).
1. Resize the default cabinet in the Cabinet panel.
Model → Cabinet
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 modi-
fication toolbar. Resizing of the cabinet object can also be done in the geometry
window in the lower right hand corner of the GUI.
a. In the Cabinet panel, click the Geometry tab.

b. Under Location, enter the following coordinates:
xS 0 xE 0.075
yS 0 yE 0.25
zS 0 zE 0.356
c. Click Done to resize the cabinet and close the panel.

d. 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 ( ).
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 icon ( ) in the model toolbar.
2. 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. Click the Edit object button ( ) to open the Blocks panel.
c. Click the Geometry tab.
d. Enter the following coordinates for the block:
xS 0 xE 0.006
yS 0 yE 0.25
zS 0 zE 0.356
e. Click Done to modify the block and close the panel.

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. Click the Edit object button ( ) to open the Openings panel.
d. Enter the following coordinates for the opening:
xS 0.006 xE 0.075
yS 0 yE 0.25
zS 0.356 zE —
e. Click Done to modify the opening and close the panel.

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. Click the Edit object ( ) to open the Fans panel.
d. Enter the following coordinates for the fan:
xC 0.04
yC 0.0475
zC 0
e. Enter 0.03 for the external radius (Radius), and 0.01 for the internal radius (Int Radius).
f. Click the Properties tab.

g. Keep the default Fan type of intake.
h. 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 select-
ing cfm from the drop-down list.
i. Click Done to modify the fan and close the panel.

5. Copy the first fan (fan.1) to create the second and third fans (fan.1.1 and fan.1.2).
a. In the graphics display window, select fan.1 using the Shift key and right mouse button.
b. In the object context menu, select Copy and the Copy fan fan.1 panel opens.
c. Enter 2 as the Number of copies.
d. Enable the Translate option and specify a Y offset of 0.0775 m.
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. Click the Edit object button ( ) to open the Sources panel.

d. Keep the default selection of Rectangular.
e. In the Plane drop-down list, select Y-Z.
f. Enter the following coordinates for the source:
xS 0 xE —
yS 0.0315 yE 0.0385
zS 0.1805 zE 0.2005
g. Click the Properties tab.

h. Under Thermal specification, set the Total power to 33 W.
i. Click Done to modify the source and close the panel.

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. In the Model manager window, select the source.1 item under the Model node.
b. Click the Copy object button ( ).

c. 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. Click the Edit object button ( ) to open the Plates panel.
d. In the Plane drop-down list, select X-Z.
e. Enter the following coordinates for the plate:
xS 0.006 xE 0.075
yS 0.0125 yE —
zS 0.05 zE 0.331
f. Click the Properties tab.

g. Under Thermal model, select Conducting thick from the drop-down menu.
h. Set the Thickness to 0.0025 m.
i. Keep default as the Solid material.
Note
Since the default solid material is extruded aluminum, you need not specify the
material explicitly here.
j. Click Done to modify the plate and close the panel.

9. Copy the first fin (plate.1) to create the other nine fins (plate.1.1, plate.1.2, ..., plate.1.9).
a. In the Model manager window, select the plate.1 item under the Model node.
b. Click the Copy object button ( ).

c. 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 ( ).
Figure 2.2 Completed Model for the Finned Heat Sink
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.
2.6. Step 3: Generate a Mesh

You will generate the mesh in two steps. First you will create a coarse mesh and examine it to determine
where further mesh refinement is required. Then you will refine the mesh based on your observations
of the coarse mesh.
Extra
For more information on how to refine a mesh locally, refer to Refining the Mesh Locally in
the Icepak User's Guide.
Extra
You can also generate a mesh by clicking the Generate mesh button ( ), which opens the
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 (minimum-
count) mesh, shown in the panel below.
b. Set the Mesh units and all the Minimum gap units to mm.
c. Set the Minimum gap to 1 mm for X, Y, and Z.
d. Set the Max X size to 3.5, the Max Y size to 12.5, and the Max Z size to 17.5.
Step 3: Generate a Mesh
e. Click the Generate button to generate the coarse mesh.
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 con-
tinue generating the mesh.
2. Examine the coarse mesh on a cross-section of the model.
a. Click the Display tab.
b. Turn on the Cut plane option.

c. In the Set position drop-down list, select X plane through center.
d. 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.
Figure 2.3 Coarse Mesh on the y-z Plane
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. Click the Settings tab.
b. 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. Click the Generate button in the Mesh control panel to generate the finer mesh.
5. 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.
Figure 2.4 Fine and Coarse Mesh on the y-z Plane
6. Turn off the mesh display.

a. Click the Display tab in the Mesh control panel.
b. Deselect the Display mesh option.
c. Click Close to close the Mesh control panel.
Step 4: Physical and Numerical Settings
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.
Figure 2.5 Display mesh option
2.7. Step 4: Physical and Numerical Settings

Before starting the solver, you will first review estimates of the Reynolds and Peclet numbers to check
that the proper flow regime is being modeled.
1. Check the values of the Reynolds and Peclet numbers.
Solution settings → Basic settings
a. Click the Reset button. Reset calculates the Reynolds and Peclet numbers.
b. 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. Click Accept to save the solver settings.

2. Enable turbulence modeling.

a. In the Basic parameters panel, select Turbulent as the Flow regime.
b. Keep the default Zero equation turbulence model.
a. Turn radiation off by clicking Off under Radiation.
Step 6: Calculate a Solution
b. Click Accept to save the new settings.
2.8. Step 5: Save the Model

ANSYS Icepak automatically saves the model for you before it starts the calculation, but it is a good
idea to save the model (including the mesh) yourself as well. If you exit ANSYS Icepak before you start
the calculation, you will be able to open the job you saved and continue your analysis in a future ANSYS
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
Note
Alternatively, you can click the button in the File commands toolbar.
2.9. Step 6: Calculate a Solution

1. Start the calculation.
Solve → Run solution
Note
You can click the Run solution button ( ) in the Model and solve toolbar.
2. Keep the default settings in the Solve panel.

3. 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 re-
siduals 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).
Step 7: Examine the Results
Figure 2.6 Residuals
4. Click Done in the Solution residuals window to close it.
2.10. Step 7: Examine the Results

ANSYS Icepak provides a number of ways to view and examine the solution results, including:
• plane-cut views
• object-face views
The following steps illustrate how to generate and display each view.
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 65°C.
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. In the Name field, enter the name cut-velocity.
b. 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. Click Create.
e. In the Orient menu, select Orient positive X.
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 ( ).
Figure 2.7 Velocity Vectors on the Fin Side of the Enclosure
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_velo-
city. 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. Click New in the Plane cut panel.
b. In the Name field, enter the name cut-temperature.
d. Turn on the Show contours option and click Parameters.
The Plane cut contours panel opens.
e. Keep the default selection of Temperature.

f. For Shading options, keep the default selection of Banded.
g. For Color levels, select Calculated and then select This object from the drop-down list.
h. 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 direc-
tions.
Figure 2.8 Temperature Contours on the Fin Side of the Enclosure
j. In the Plane cut panel, turn off the Active option.

4. Display velocity vectors superimposed with pressure contours.
a. Click New in the Plane cut panel.
b. In the Name field, enter the name cut-prvelocity.
d. Specify the display of velocity vectors.
i. Turn on the Show vectors option and click Parameters.
The Plane cut vectors panel opens.

ii. Select Fixed from the Color by drop-down list.
iii. Click on the square next to Fixed color and select black from the color palette.
iv. Click Done to close the panel.
e. Specify the display of contours of pressure.
i. Turn on the Show contours option and click Parameters.
The Plane cut contours panel opens.

ii. In the Plane cut contours panel, select Pressure in the Contours of drop-down list.
iii. For Shading options, keep the default selection of Banded.
iv. For Color levels, select Calculated and then select This object from the drop-down list.
v. 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.
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. In the Plane cut panel, turn off the Active option.

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. In the Name field, enter the name face-tempsource.

c. 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.
d. Turn on the Show contours option.
e. Click Parameters next to the Show contours option.
The Object face contours panel opens.

f. In the Object face contours panel, keep the default selection of Temperature in the Contours
of drop-down list.
g. For Shading options, keep the default selection of Banded.
h. For Color levels, select Calculated and then select This object from the drop-down list.
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 tem-
perature distributions are similar for all sources: warm in the center and decreasing in tem-
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.
Figure 2.10 Temperature Contours on the Five Devices
k. In the Object face panel, turn off the Active option.

6. Display line contours of temperature on the backing plate.
a. Click New in the Object face panel.
b. In the Name field, enter the name face-tempblock.
c. In the Object drop-down list, select block.1 and click Accept.
d. Turn on the Show contours option and click Parameters.
The Object face contours panel opens.

e. In the Object face contours panel, keep the default selection of Temperature in the Contours
of drop-down list.
f. For Contour options, deselect Solid fill and select Line.
g. For Level spacing, select Fixed and set the Number of contour lines to 200.
h. For Color levels, select Calculated and then select This object from the drop down list.
Step 8: Summary
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.
Figure 2.11 Temperature Contours on the Backing Plate
j. Click Done in the Object face panel to close the panel.

7. Save the post-processing objects created.
a. Select Save post objects to file in the Post menu.
b. 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.
2.11. Step 8: Summary

In this tutorial, you set up and solved a model in order to determine the ability of the specified heat
sink to maintain source temperatures below 65 °C. Postprocessing results show that the maximum
source temperature is about 60 °C, indicating that the heat sink provides adequate cooling for the
sources.
2.12. Step 9: Additional Exercise

To determine the effectiveness of the heat sink under conditions involving the failure of the middle
fan, deactivate or edit fan.1.1, go to the Properties tab and turn on Failed under the Options tab,
assign a free-area ratio of 0.3, and click Done. Next, remesh the model, solve it again using a different
solution ID, and examine the new results.
Note
When you are finished examining the results, you can end the ANSYS Icepak session by
clicking Quit in the File menu.
File → Quit
Chapter 3: RF Amplifier
3.1. Introduction
This tutorial demonstrates how to model an RF Amplifier using ANSYS Icepak.
• 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.
3.2. Prerequisites
This tutorial assumes that you have little experience with ANSYS Icepak, but that you are generally fa-
miliar with the interface. If you are not, please review Sample Session in the Icepak User's Guide.

RF Amplifiers are typically sealed enclosures that are placed within larger systems. They present a
challenge from the thermal management perspective because no direct exchange of air exists between
the interior of the amplifier and the ambient. The common method of cooling such subsystems is to
mount a large heat sink on the amplifier housing that cools all the devices within the enclosure. A
simplified version of an RF amplifier (Figure 3.1 (p. 38)) will serve as the model for this tutorial. There
will be free convection inside the amplifier and forced convection in the external domain.
Figure 3.1 Schematic of the RF Amplifier

1. Start ANSYS Icepak, as described in Chapter 1 of the User's Guide.
3. Specify the name amplifier for your project and click Create.
Note

To build the model, you will first resize the cabinet to its proper size. Then you will create the amplifier
housing, devices (heat sources), PCB, heatsink, fan and other geometrical objects.
1. Resize the default cabinet and create an opening on one side of the cabinet.
Model → Cabinet
Select the cabinet in the Model tree and specify the following in the object geometry window:
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
Figure 3.2 The Cabinet Geometry Tab Panel
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. Change the Max y Wall type to be an Opening.
b. Click Done to accept the inputs and close the panel.
Figure 3.3 The Cabinet Boundary Panel
2. Create the Y and Z faces of the amplifier housing as an enclosure using the enclosure object.
Click on the Create enclosures icon ( ) in the model toolbar, then specify the following Name
and dimensions:
In the Properties tab specify the followings:

a. Change the Boundary type to Open for Min X and Max X. For others, retain the boundary type
as Thin.
b. Specify the Solid material as Polystyrene-rigid-R12.
Tip
You have to scroll down the list to find this material.
c. Click Done.
Figure 3.4 The Enclosure Panel
3. Create the Xmin face of the amplifier housing as a wall.
The wall covers the Xmin side of the enclosure.

4. Click on the Create walls icon ( ) in the model toolbar to create a new wall.
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 ( ) in the model toolbar. Now, follow the step-
by-step procedure described below:
a. 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.
b. Click the middle mouse button to accept this edge.
c. 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.
Figure 3.5 Schematic Showing Edge Identities for Alignment
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.
b. Click the middle mouse button to accept.
c. Using the left mouse button, click the lower Zmin edge of the enclosure.
d. Click the middle mouse button to accept. The wall should now form the Xmin face of the enclosure.
e. Click the right mouse button to exit the Match edge mode.
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.
Figure 3.6 Geometry with Wall
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. Specify a Wall thickness of 1 mm (0.001 m).
b. Specify the Solid material as Polystyrene-rigid-R12 under Plastics.
c. Specify the External conditions as Heat transfer coefficient and click the Edit button.
The Wall external thermal conditions panel opens.
i. Select Heat transfer coefficient in the External conditions drop-down list and press Edit.
The Wall external thermal conditions panel opens.
ii. Set the Heat transfer coeff to 5 W/K-

.
iii. Click Done to close the Wall external thermal conditions panel.
iv. Click Done to close Walls panel (Figure 3.7 (p. 45))
Figure 3.7 The Walls Panel
5. Create the PCB.
The PCB will cover the Xmax side of the enclosure.

a. Click on the Create printed circuit boards icon ( ) in the Model toolbar to create a PCB and
double click on the PCB object in the Model tree.
b. Specify the following in the geometry window:
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)).
Figure 3.8 The Printed circuit boards Panel
d. Click Done to close the Printed circuit boards panel.

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 re-
maining 11 sources.
a. 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.
b. Specify the following name, dimensions, and properties to the source.
c. In the Properties tab, specify the Total power as 7 W (Figure 3.9 (p. 47)) and click Done.
Figure 3.9 The Sources Panel
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. Right mouse click on the source object and choose the Copy option.
ii. Specify the Number of copies as 2.
iii. Turn on the Translate option.
iv. Specify the Z offset to 0.055 m.
v. Click Apply to copy the object.
Figure 3.10 The Copy source device Panel
e. Similarly, create the other devices (sources) object by copying the sources created in the previous
steps.
i. 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.
ii. Specify the Number of copies as 3.
iii. Turn on the Translate option.
iv. Specify the Y offset to 0.064 m.
v. 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.
Figure 3.11 Geometry with Devices
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.
b. 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.
c. 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.
Figure 3.12 The Heat sinks Panel
d. Click Done to close the Heat sinks panel.

8. Create the fan.
For this model, we will make use of ANSYS Icepak's fan library and search tool.
a. Select the Library tab in the model manager window(Figure 3.13 (p. 51)).
b. Right-click on Libraries in the model tree and choose Search fans.
The Search fan library dialog appears.

i. In the Physical tab, deactivate the Min fan size and enter 80 mm for the Max fan size.
ii. Select the Thermal/flow tab, enable the Min flow rate option and specify a Min flow rate
of 80 cfm.
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. Select the fan called delta.FFB0812_24EHE in the Name column by clicking on it with the
left mouse button.
d. Click Create to load the fan into the model.
Figure 3.13 Search Fan library Panel
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).
Figure 3.14 The Fans Panel
The final geometry should look like Figure 3.15 (p. 53).
Step 3: Create Assemblies
Figure 3.15 The Final Geometry
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.
3.6. Step 3: Create Assemblies

For both organizational purposes and to have a finer mesh in the fan and enclosure, we will create two
assemblies. The first assembly will consist of the RF amplifier and heat sink; the second assembly will
consist only of the fan.
1. To create the amplifier assembly:

a. 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.
b. While pressing Shift, drag a bounding box around the amplifier using the left mouse button. Re-
lease the mouse button and notice that all of the objects forming the amplifier and heat sink
have been selected in the model tree.
c. 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.
d. In the Object geometry window, rename the assembly “assembly.1" to amplifier and click
Apply.
2. Create a new assembly for the fan object:
a. Click on the Create assemblies icon ( ) in the model toolbar to create a new assembly.
b. 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.
c. In the Object geometry window, rename this assembly as fan and click Apply.
Figure 3.16 Two Assemblies

Before generating a mesh, we will specify the slack values for the assemblies. Slack values represent a
finite offset from an object to a non-conformal mesh boundary and are required when meshing assem-
blies separately.
1. Edit both assemblies (right-click the assembly name in the model toolbar and select Edit), then select
the Meshing tab.
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.
Table 3.1 Slack Values for the Amplifier and Fan

Name Min X Min Y Min Z Max X Max Y Max Z
Amplifier 0 0.02 0.01 0 0.05 0.01
Fan 0.01 0 0.01 0.01 0.05 0.01
Figure 3.17 Fan Assemblies Panel
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 ( ) in
the shortcut menu.
Figure 3.18 The Mesh control Panel
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. To view the mesh, display a plane-cut view through the center of the cabinet, perpendicular to the
fins (y-z plane).
6. To create a plane-cut, follow these steps:
a. Click on the Display tab at the top of the Mesh control panel.
b. Toggle on Display mesh and Cut plane.
c. Under Plane location, set position to X plane through center in the drop-down list.
d. Press Shift+X to orient to the positive X direction and view the newly created plane cut.
e. 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
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.
Figure 3.19 Coarse and Fine Mesh
8. Once you have explored the mesh quality, click Close to dismiss the Mesh control dialog box.

Before starting the solver, you will first review estimates of the Reynolds and Peclet numbers to check
that the proper flow regime is being modeled.
1. Check the values of the Reynolds and Peclet numbers.

a. Click the Reset button.
b. 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.
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. Click Accept to save the solver settings.

2. Enable turbulence modeling.

a. In the Basic parameters panel, select Turbulent as the Flow regime and keep the default Zero
equation turbulence model.

b. Turn on the Gravity vector option and make sure that gravity in the y-direction is -9.8 m/
Note
Specifying gravity is important for the natural convection inside the RF amplifier.
c. Turn off radiation.

d. Click Accept to save the new setting.
The panel appears as shown in Figure 3.20 (p. 60).
Figure 3.20 Basic parameters Panel
3. Return to the Basic settings panel, specify the number of iterations as 300, click Reset and then Accept
again.
4. Set up the temperature limits for all the sources.
Model → Power and temperature limits

a. Enter a new value of 60°C for Default temperature limit.
b. Click on All to default.
c. 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.

ANSYS Icepak will save the model for you automatically before it starts the calculation, but it is a good
Note
You can click the save button ( ) in the File commands toolbar.

1. Create monitors.
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. Drag device.2 and cabinet_default_side_maxY into the Points folder.

b. Right mouse click on the cabinet_default_side_maxY in the Points folder.
c. Select Edit and deselect temperature and activate Velocity (Figure 3.21 (p. 61)).
d. Click Accept to accept the modifications and to dismiss the per-object's Modify point panel.
Figure 3.21 The Modify point Panel
2. Start the calculation.
Note
Alternatively, you can click on the Run solution icon ( ) in the model and solve
toolbar to display the Run solution panel.
a. Enable Write overview of results when finished in the Results tab.

b. 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).
Figure 3.22 Convergence Plot
Figure 3.23 Monitor Plot

Once the model has converged (Figure 3.22 (p. 62) and Figure 3.23 (p. 63)), ANSYS Icepak automatically
generates a solution overview report. This report contains detailed information, such as object-based
mass and volumetric flow rates, fan operating points, heat flows for objects with specified power, heat
flows for objects that communicate with the ambient, maximum temperatures, and overall balances.
Please carefully review the solution overview and note that the solution satisfies conservation of mass
and energy (scroll to the bottom of the report). Also note the fan operating point. The solution overview
is automatically saved and can be reopened from Report → Solution overview → Create.
1. Compare the object temperature values for all sources with the temperature limits assigned.
Post → Power and Temperature values
The Power and temperature limit setup window appears.

a. Click Show too hot.
The Power and Temperature limit setup show the default temperature limit and the resulting
maximum temperature value for each source next to them.
If an assembly is expanded in the model tree and if the resulting temperature of any object
exceeds the temperature limit specified, ANSYS Icepak shows all the critical objects in red
color.
b. Click Accept to close the dialog box.
2. Create object faces.
Note
Ensure that the amplifier and fan assemblies are expanded, so that the fins are visible.
a. Press Shift+Z to orient the view in the positive Z direction.
b. To create an object face, click the Object face icon ( ) in the shortcut toolbar.
c. In the Object drop down list, specify heatsink.1 as the object and click Accept.
d. Select Show contours and click the Parameters button (adjacent to show contours) to access
the Object face contours edit dialog box.
i. Select This object in the drop-box adjacent to Calculated to use the object-based range.
ii. Click Done to close the Object face contours panel.
e. Click Done to close the Object face panel.
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.
Figure 3.24 Object Face Panel
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)).
Figure 3.25 Temperature Contours on the Face
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. To create a plane cut, click the Plane cut icon ( ) in the shortcut toolbar.
b. 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).
Figure 3.26 Plane Cut
c. Click the Parameters button adjacent to Show vectors.

d. 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.
e. 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)).
Figure 3.27 Velocity Vectors on the Mid X Plane
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.
b. Specify Temperature as the Variable, input a Value of 55°C, 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.
c. 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 55°C (Figure 3.28 (p. 68)).
Figure 3.28 Isosurface of Temperature 55°C
d. 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)).
e. Once you have examined the isosurface, delete or deactivate it using one of the previously de-
scribed methods.
Figure 3.29 Isosurface of Speed 4 m/s
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. Specify the Variable as UY.
ii. Click the From screen button.
iii. Click the left mouse button on the center on the heat sink fins.
iv. Click Create.
c. 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.
d. Save the xy-plot.
i. Click the Save button at the bottom of the Variation of UY plot window.
ii. Enter a file name in the resulting Save curve dialog box.
iii. Click Save to save the file in the model folder.

In this tutorial, you have learned about the usage of enclosure, PCB, source and heat sink objects. The
use of ANSYS Icepak's fan library and search tool has been explained. Meshing of assemblies and post-
processing features in ANSYS Icepak were also explained.
Chapter 4: Use of Parameterization to Optimize Fan Location
4.1. Introduction
The purpose of this tutorial is to demonstrate the following ANSYS Icepak features with the help of a
small system level model.
• Use network blocks as one way of modeling packages.

• Specify contact resistance using side specifications of a block object.
• Define a variable as a parameter and solve the parametric trials.
• Specify fan curves.
• Use local coordinate systems.
• Generate a summary report for multiple solutions.
4.2. Prerequisites
miliar 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.

The system level model consists of a series of IC chips on a PCB. A fan is used for forced convection
cooling of the power dissipating devices. A bonded fin extruded heat sink with eight 0.008 m thick fins
is attached to the IC chips. The fan flow rate is defined by a nonlinear fan curve. The system also consists
of a perforated thin grille. A study is carried out for the optimum location of the fan by using the
parameterization feature in ANSYS Icepak.
Figure 4.1 Schematic of the Geometry

3. Specify a name for your project (i.e., fan_locations) and click Create.
cabinet in the graphics window. This cabinet will be modified in the next section.

1. Resize the default cabinet.
The cabinet forms the boundary of your computational model. Press the isometric view icon ( )
for a 3D view. Select Cabinet in the Model manager window and enter the location values as
shown in the panel below. The geometry window can be found in the lower right hand corner
of the GUI.
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.
Figure 4.2 The Param value Panel
We will now set the physical properties that will define the fan behavior:
a. Edit the fan object and go to Properties tab.
b. In the Properties tab, retain the selection of Intake for Fan type and select Non-linear in the
Fan flow tab.
c. Enter the characteristic curve by clicking on the Edit button and selecting Text Editor in the drop-
down list in the Non-linear curve group box.
Figure 4.3 The Fans Panel (Properties Tab)
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.
Table 4.1 Values for the Curve Specification Panel

Volume Flow (CFM) Pressure (in_water)
0 0.42
20 0.28
40 0.2
60 0.14
80 0.04
90 0.0
e. Click Accept to close the form.

f. Select the Edit button again in the Non-linear curve group box and click on Graph Editor in the
drop-down list to view the fan curve (Figure 4.4 (p. 75) ).
Figure 4.4 The Fan Curve Panel
g. Click Done to close the Fan curve panel.

h. In the Properties tab, give the fan an RPM of 4000 in the Swirl tab, located next to the Fan flow
tab.
i. 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 accord-
ing 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.
Now the model looks as shown in Figure 4.5 (p. 76).
Figure 4.5 Model with Fan
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. Under velocity loss coefficient, retain the default selection of Automatic.

ii. Specify a Free area ratio of 0.5.
iii. Retain Perforated thin vent for the Resistance type.

iv. 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).
Figure 4.6 Model with Fan and Grill
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 phys-
ical parameters for the wall object:
i. Make the plane xz.
ii. Use the morph faces icon ( ) from the model toolbar so that the wall object covers the
entire min-Y floor of the cabinet.
iii. Edit the Wall object and go to Properties tab.
iv. In the Material group box, set the Wall thickness to 0.01 m and the Solid material to FR-
4.
v. In the Thermal specification group box, specify a Heat flux of 20 W/m2.

vi. Click Update and then Done to close the panel.
After creating the wall, the model looks as shown in Figure 4.7 (p. 78).
Figure 4.7 Model with Wall Added
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:
i. In the Surface specification group box, click on the Individual sides check box and click
Edit (Figure 4.8 (p. 79)).
A. Select MinY and toggle on Thermal properties and Resistance.
B. Under Thermal condition, retain the selection of Fixed heat and Total power of 0
W.
C. Select Thermal resistance from the drop-down menu next to Resistance.
D. Set Thermal resistance to 0.005 C/W and click Accept.
E. Click Accept to close the panel.
Figure 4.8 The Individual side specification
ii. 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).
iii. Set Total Power to 5 W.
iv. Click Update and Done to close the panel.
c. Next, make three copies of this block with an X offset of 0.08 m.
Extra
The previous tutorial showed you how to make a copy of an object.
Figure 4.9 Creation of Solid Blocks
• 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).
Figure 4.10 The Properties Panel
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.
• Creation of a Hollow Block
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. Create a new Block; make sure it is a hollow.

b. In the Geometry tab, create a new Local coord system.
c. Select Create new from the Local coord system: drop-down list.
d. Enter X offset = 0.1, Y offset = 0, Z offset = 0.
e. Click Accept. This is just to demonstrate the use of local coordinate system.
f. Further, size the block as follows:
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 ( ) and edit it, entering its location and properties as shown
in the following table:
Table 4.2 Heatsink Properties

Geometry
Plane: xz
xS/xE: 0.02/0.34
yS/yE: 0.03/—
zS/zE: 0.1/0.23
Base height: 0.01 m
Overall height: 0.06 m
Properties
Type: Detailed
Flow Direction: X
Detailed Fin type: Bonded fin
Fin setup
Fin spec: Count/thickness
Count: 8
Thickness: 0.008 m
Flow/thermal data
Fin material: default
Base material: Cu-Pure
Interface
Fin bonding: Click the Edit button
Effective thickness: 0.0002 m
Solid material: default
b. Click Update and Done. This completes the model building process. The complete model should
look like that shown in Figure 4.11 (p. 83).
Step 3: Creating Separately Meshed Assemblies
Figure 4.11 Final Model
4.6. Step 3: Creating Separately Meshed Assemblies

One of the key aspects of modeling is to use an adequate mesh for the model. We need to have a fine
mesh in the areas where temperature gradients are high or flow is turning. Having a too coarse of a
mesh will not give you accurate results and at the same time, too fine a mesh may lead to longer run
times. The best option is to explore the model carefully and look for opportunities to reduce mesh
counts in the areas where the gradients are not steep. Creating non-conformal assemblies gives required
accuracy along with reduced mesh count. Select set of objects to create assemblies. Also decide suitable
slack values for assembly bounding box. Your selection can be reviewed in the section below where
we will create non-conformal meshed assemblies.
We will now create two non-conformal meshed assemblies.
1. To create the first assembly, first highlight all the blocks (except the hollow block) and the heat sink
object in the model tree, then right-click on them and choose Create and then Assembly.
2. Right-click and select Rename from the menu. Rename the assembly, as Heatsink-packages-asy.
3. To build the “bounding box" for the assembly called Heatsink-packages-asy, double-click on it to
edit the assembly.
4. In the Meshing tab of the Assemblies panel, toggle on Mesh separately, and then set the Slack
parameters as the following:
Table 4.3 Slack Values for Heatsink-packages-asy Assembly

Min X 0.005 m Max X 0.015 m
Min Y 0.005 m Max Y 0.005 m

Min Z 0.005 m Max Z 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 Fan-
asy). Use the following table to assign the Slack values for the Fan-asy assembly.
Table 4.4 Slack Values for Fan-asy Assembly

Min X 0m Max X 0.005 m
Min Y 0.002 m Max Y 0.002 m
Min Z 0.002 m Max Z 0.002 m

To generate the mesh:
1. Open the Mesh control panel, keep the default values for the mesh settings and ensure that Mesh
assemblies separately is on.
2. Click Generate. You will get a warning about minimum separation if the Allow minimum gap changes
option is unchecked in the Misc tab.
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 tu-
torial and may not be applicable all the time. As separation setting is a useful tool de-
signed 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. Click on Change value and mesh.

4. Examine the mesh by taking plane cuts; examine Face alignment and Quality ratio.
5. Go to the Mesh control panel, click on the Display and Quality tabs to examine the mesh.
4.8. Step 5: Setting up the Multiple Trials

Before we start solving the model, we will set up the parametric trials for the fan location parameter
“zc".
Step 5: Setting up the Multiple Trials
1. Go to the Solve menu and select Define trials.

a. The Parameters and optimization panel pops up.
b. Toggle on Parametric trials in the Setup tab.
c. 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.
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.
Figure 4.13 The Parameters and optimization Panel- Trials tab
3. Click Done to close the Parameters and optimization panel.
4.9. Step 6: Creating Monitor Points

Create two monitor points by dragging and dropping (block.1 and grille.1) into the Points folder to
monitor the velocity in the grille and the temperature in one of the solid blocks. The variables to be
monitored can be easily changed by selecting them in the Monitor points panel.
Step 7: Physical and Numerical Setting
Figure 4.14 The Modify point Panel
4.10. Step 7: Physical and Numerical Setting

Set up the basic problem parameters to solve the flow and energy equations, and use the Zero equation
turbulence model. Since natural convection is not involved, there is no need to turn on the Gravity
vector.
Figure 4.15 The Basic parameters Panel
Enter 200 in the Number of iterations field in the Basic settings panel.
Figure 4.16 The Basic settings Panel

ANSYS Icepak saves the model for you automatically before it starts the calculation, but it is a good
Alternatively, click the save button ( ) in the file commands toolbar.

The Solve panel is used for single trials only; therefore, the solution can only be calculated from the
Parameters and optimization panel. Open the Parameters and optimization panel and click Run to
calculate a solution for both trials.
Figure 4.17 The Parameters and optimization Panel- Trials tab

Once the solutions are done, click on the Post menu and select Load solution ID. Select the solution
that corresponds to the first (parametric) run, i.e., zc = 0.1. If you want to view objects inside the assem-
blies, you can open all the model nodes by right mouse clicking Model in the Model manager window
and selecting Expand all. Use the various postprocessing features available in ANSYS Icepak to display
your solution. A description of how to generate plane cut and object face views can be found in Step
7: Examine the Results of the Finned Heat Sink tutorial. In particular, use the following views:
1. Plane cut panel to display the velocity vectors on a plane through the cabinet
Figure 4.18 Trial 1 Vector Plots at Constant Z Plane Cut
Figure 4.19 Trial 2 Vector Plots at Constant Z Plane Cut
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
Figure 4.20 Trial 1 Temperature Contours on Blocks and PCB (wall.1)
Figure 4.21 Trial 2 Temperature Contours on Blocks and PCB (wall.1)
3. Object face panel to display temperature contours on the faces of the PCB (wall.1) and on all blocks
4. Surface probe panel to display the temperature values at a particular point
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 tem-
perature 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.
4.14. Step 11: Reports

1. Overview Report
At the end of the runs, ANSYS Icepak automatically displays an overview report because you se-
lected Write overview of results when finished in the Solve panel. This report has:
• fan operating point
• volume flow rate through the grille
• heat flow from the chips
• network junction temperatures
• heat flows for the wall and the grille.
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.

In this tutorial, you learned how to set up and solve parametric trials, specify fan curves and create a
new local coordinate system. The use of network blocks to model packages has been demonstrated as
well as how to specify contact resistance using side specifications of a block object. You also learned
how to generate a summary report for multiple solutions.
4.16. Step 13: Additional Exercise to Model Higher Altitude Effect

The final model can also be used to model the effects of higher altitudes. In order to model this correctly,
new air properties at the particular altitude need to be defined and assigned to the default fluid. The
density of air is the most affected property and gets lower as you go higher in altitude. The data for
air properties at a different altitude is presented in many handbooks and may even include temperature
change affect with it. For an altitude of 3000 m, we can select the available library material Air@3000m.
Please note that a custom material having any properties can be created and stored in the material
library to use in any project.
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.
Step 13: Additional Exercise to Model Higher Altitude Effect
Chapter 5: Cold-Plate Model with Non-Conformal Meshing
5.1. Introduction
This tutorial demonstrates how to model a cold-plate using ANSYS Icepak.
• Use the priorities of different objects to model complex shapes in ANSYS Icepak.
• Use multiple fluids in a model.
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.

The model consists of a cold-plate, where the cold-plate fluid is transporting a significant fraction of
the heat from two plates mounted on either side of it. The natural convection in the external air is also
instrumental in some heat transfer. The model setup is shown in Figure 5.1 (p. 101).
The objective of this exercise is to illustrate the use of two different fluids in ANSYS Icepak. The model
includes two heated plates, cooled by water circulating inside the cold-plate cavity, as well as by air
driven by natural convection externally. Separately meshed assemblies will be employed to reduce the
overall mesh count in the domain. The model will be constructed using the default metric unit system.

Create a new project called cold-plate.

Construct the cabinet and all the other objects according to the following specifications. Note that
during the model building, you may use the alignment tools. Please remember that you can align the
face, edge and vertex of one object with another. For example, you could align the bottom face of the
cylinders to the cabinet (see Figure 5.1 (p. 101)). You may also use the align tools to create the openings
on the cold-plate inlet and outlet regions.
• Cabinet
Enter the following start and end locations for the cabinet
Table 5.1 Cabinet Start and End Values

xS 0.0 m xE 0.4 m
yS 0.0 m yE 0.3 m
zS 0.0 m zE 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.
Table 5.2 block.1 and block.2 Specifications

block.1 xS 0.05 m xE 0.35 m
Geometry: Prism yS 0.08 m yE 0.22 m
Block type: Solid zS 0.07 m zE 0.13 m
Solid material: Al-Extruded
block.2 xS 0.06 m xE 0.34 m
Geometry: Prism yS 0.09 m yE 0.21 m
Block type: Fluid zS 0.08 m zE 0.12 m
Fluid material: Water (@280K)
Because block.2 is being created after block.1, it will have a higher relative meshing priority.
Note
Because Al-Extruded is set as the Default solid in the Defaults tab of the Basic para-
meters 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.
Table 5.3 Cylindrical Block Specifications

Object xC yC zC Height Radius IRadius Specifications
block.3 0.1 0.0 0.1 0.09 m 0.015 0.0 m Block type: Solid
m m m m
Geometry: Solid material: Al-Extruded
Cylinder
Plane: X-Z
block.4 0.3 0.0 0.1 0.09 m 0.015 0.0 m Block type:Solid
m m m m
Geometry: Solid material: Al-Extruded
Cylinder
Plane: X-Z
block.5 0.1 0.0 0.1 0.09 m 0.01 m 0.0 m Block type: Fluid
m m m
Object xC yC zC Height Radius IRadius Specifications

Geometry: Fluid material: Water(@280K)
Cylinder
Plane: X-Z
block.6 0.3 0.0 0.1 0.09 m 0.01 m 0.0 m Block type: Fluid
m m m
Geometry: Fluid Material: Water(@280K)
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.
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
Table 5.4 Plate Specifications

Object Specifications
plate.1 xS 0.07 m xE 0.33 m Solid material:
Geometry: Rectangular yS 0.1 m yE 0.2 m Al-Extruded
Plane: X-Y zS 0.06 m zE — Power: 200W
Thermal model: Conducting thick: 0.01 m
plate.2 xS 0.07 m xE 0.33 m Solid material:
Geometry: Rectangular yS 0.1 m yE 0.2 m Al-Extruded
Plane: X-Y zS 0.13 m zE — Power: 200W
Thermal model: Conducting thick: 0.01 m
Note
Note: An alternative way to create plate.2 would be to copy plate.1 with a Z offset of
0.07m.
• Openings
The openings at the liquid inflow and outflow regions of the cold-plate are
Table 5.5 Opening Specifications

Object xC yC zC Radius Specifications
opening.1 (outlet opening) 0.1 m 0m 0.1 m 0.01 m
Type: Free
Geometry: Circular
Plane: X-Z
opening.2 (inlet opening) 0.3 m 0m 0.1 m 0.01 m Y velocity = 0.2 m/s
Type: Free
Geometry: Circular
Plane: X-Z
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
Table 5.6 Openings at Cabinet Boundary Specifications

Object
opening.3 xS 0.4 m xE —
Type: Free yS 0.0 m yE 0.3 m
Geometry: Rectangular zS 0.2 m zE 0.0 m
Plane:Y-Z
opening.4 xS 0.0 m xE —
Type: Free yS 0.0 m yE 0.3 m
Geometry: Rectangular zS 0.2 m zE 0.0 m
Plane:Y-Z
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).
Step 3: Create a Separately Meshed Assembly
Figure 5.1 The cold-plate Model
Note
Figure 5.1 (p. 101) has changed the opacity, shading and color of some objects to make
the objects easier to see.
5.6. Step 3: Create a Separately Meshed Assembly

To create a separately meshed assembly, highlight all the objects in the model tree other than the
cabinet, opening.3, and opening.4. Right mouse click on them and choose Create and then Assembly.
To enable separate meshing for the assembly, double-click on assembly.1 to edit the assembly. Under
the Meshing tab, toggle on the Mesh separately button and then enter the slack values as follows:
Table 5.7 Slack Values for Mesh Assembly

Min X 0.01 m Max X 0.01 m
Min Y 0.0 m Max Y 0.01 m
Min Z 0.01 m Max Z 0.01 m
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.

Open the Mesh control panel, make sure that the Mesh assemblies separately option is toggled on
and Normal mesh is selected for Mesh parameters. Change the Max size ratio to 4 and keep the
other global default mesh settings. The mesh needs to be refined for the inner prismatic fluid block
(block.2). In the Misc tab, make sure Allow minimum gap changes is checked. Then toggle on Object
params and click Edit in the Local tab. Choose block.2 and check Use per-object parameters and
enter 30, 16, and 10 respectively for the X, Y and Z counts for the mesh in the fluid block, as shown in
the following figure. Click Done to close the Per-object meshing parameters panel.
Click Generate to mesh the model. Visualize the mesh at plane cuts and surface displays from the
Display tab.

A calculation of the Reynolds number shows that the problem is turbulent. To set up turbulent flow,
go to Problem setup → Basic parameters and choose the Zero equation turbulence model
for the Flow regime in the General setup tab.
Gravity acts in the negative x direction in this problem. To setup the effects of gravity, toggle on the
Gravity vector in the General setup tab. Enter the new values for the gravity vector as x = -9.80665,
y = 0 and z = 0. Now go to the Transient setup tab and set an initial X velocity of 0.005 m/s in the x
direction. Accept all other defaults in the Basic parameters panel. These are shown in Figure 5.2 (p. 103).
Figure 5.2 Switching on Gravity and Turbulent Flow
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.
Figure 5.3 Basic and Advanced Solver Settings
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.

idea to save the model after the model building and meshing is complete.
Alternatively, click the save button ( ) in the file commands toolbar.

Select the Solve menu and click on Run solution. In the Solve panel, under the Results tab toggle on
Write overview of results when finished, and then click Start solution.

Please review the solution overview report created to ensure that mass (volume) flow rate and energy
balances are satisfied. To postprocess the results, create the following object face and plane cut objects:
Table 5.8 Object Face and Plane Cut Specifications

Object Specifications/Display Attributes Description
face.1 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 Observation: Water is circulating through the internal
Show vectors/ Parameters channel, providing most of the cooling for the
model. On the outside, air flows over the system by
Color by: Velocity Magnitude natural convection.
Color levels: Calculated/Global limits
face.2 Objects: opening.1 (outlet) and open- Observe the flow pattern from inlet opening to
ing.2 (inlet) outlet opening passing through the cold plate. An-
Show particle traces/ Parameters imate the particle traces.
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 Set position: X plane through center Observe the flow pattern in (+) X direction. Animate
Show particle traces/ Parameters the particle traces.
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 Due to the nature of the problem, the temperature
Show contours of 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.

In this problem, we modeled a cold-plate that included two heat plates cooled by water circulating inside
the cold-plate cavity as well as air driven by natural convection externally. This exercise also demonstrated
how to use the priorities of different objects to model complex shapes in ANSYS Icepak and the use of
multiple fluids in a model.

To see the cooling capacity (effectiveness) of water, you may run the same model by replacing the fluid
properties (of the fluid blocks) by Glycol, i.e., make all the fluid blocks air blocks. You should see a sig-
nificant increase in the maximum temperature.
Chapter 6: Heat-Pipe Modeling and Nested Non-Conformal Meshing
6.1. Introduction
This tutorial demonstrates how to model simple heat pipes and an active heat sink using ANSYS Icepak.
In this tutorial, you will learn how to:
• Create orthotropic solid materials.

• Use those materials to simulate a heat-pipe in a system.
• Use of copy mirror and copy translate functions.
• Create nested non-conformal assemblies.
6.2. Prerequisites
miliar 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.

Heat pipes are used to transport heat from a heat source area (where there is limited space for heat
dissipation) to a place where it is dissipated. The objective of this exercise is not to model the detailed
physics inside a heat pipe. Instead, we will model a heat pipe by using a series of cylindrical solid blocks
that connect the heat source to an air-cooled heat sink. These blocks will have an orthotropic conduct-
ivity with very large conductivity in the pipe axis direction where the heat is carried away. The model
will be constructed using the default metric unit system. We will also make use of nested non-conformal
meshing using assemblies to reduce the cell count in the model.
Figure 6.1 Heat-pipe Tutorial Base Model

1. Copy the file ICEPAK_ROOT/tutorials/heat-pipe/heat-pipe-nested-NC.tzr to your
working directory. You must replace by the full path name of the directory where ANSYS Icepak is in-
stalled on your computer system.
Note
ANSYS Icepak can be started in ANSYS Workbench using the import .tzr feature or it
can be opened as a stand-alone product.
3. Click Unpack in the Welcome to Icepak panel.

4. In the File selection panel, select the packed project file heat-pipe-nested-NC.tzr and click
Open.
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 Un-
pack.
Note
In ANSYS Icepak, the packed file feature compresses a model to the files needed to build,
mesh and run the model (job, model and problem files). In many of the tutorials, part of the
model is already created and packed to speed up the learning process. The model originally
has three blocks and only block.1 has an assigned power (25 W). The model also has one
fan and one grille. Next, we will build a heat sink in the area of the fan, grille and the heat
pipe system to connect block.1 to the heat sink.
1. Create materials utilizing ANSYS Icepak's orthotropic material conductivity feature. The idea is to have
a material that has very high conductivity in the pipe heat removal directions but normal conductivity
in the other directions.
• Click on the material icon ( ) in the object toolbar for each new material to be created.
• Click on the material name with the right mouse button and select Edit or double click the mater-
ial 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 Con-
ductivity type to be Orthotropic from the drop-down list.
• Deselect the Edit check box next to conductivity and create the following materials with ortho-
tropic conductivity properties using the template in Figure 6.2 (p. 110).
Figure 6.2 Orthotropic Material Properties
Table 6.1 Orthotropic Properties

Name Nominal Conductivity Orthotropic multiplier
material.1 20000 X=1 Y = 0.005 Z = 0.005
material.2 20000 X = 0.005 Y=1 Z = 0.005
material.3 20000 X=1 Y=1 Z = 0.005
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 conduct-
ivity 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)
Table 6.2 Block Specifications

Object Geo- xC yC zC Height Radius IRadius Specifications
metry
pipe1 Shape: 0.05 0.11 0.1 0.245 0.01 m 0.0 m Type: Solid
Cylin- m m m m
der
Plane: Solid material:
Y-Z material.1
Object Geo- xC yC zC Height Radius IRadius Specifications

metry
Cylin- m m m m
der
Y-Z material.1
Cylin- m m m m
der
X-Z material.2
Object Geo- xS yS zS xE yE zE Specifications
metry
Joint1 Shape: 0.295 0.095 0.085 0.325 0.125 0.115 m Type: Solid
Prism m m m m m
Solid material:
material.3
Joint2 Shape: 0.295 0.35 0.085 0.325 0.38 m 0.115 m Type: Solid
Prism m m m m
Solid material:
material.3
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
Table 6.3 Base and Pin Specifications

Ob- Geo- xS yS zS xE yE zE Properties
ject metry
Base Shape: 0.42 0.35 0.05 0.592 0.38 m 0.15 m Block type: Solid
Prism m m m m
Solid material:
default
Ob- Geo- xC yC zC Height Radius Int radi- Properties
ject metry / Radi- us / Int
us 2 radius 2
Pin Shape: 0.44 0.38 0.067 0.04 m 0.01 m / 0m/0 Block type: Solid
Cylinder, m m m 0.006 m m
Plane: X- Solid material:

Z default
Non-uni-
form radi-
us
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)).
Figure 6.3 Non-uniform Cylinder
• 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).
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).
Figure 6.4 Model with Heat Pipe and Heat Sink
6.6. Step 3: Create Nested Non-conformal Mesh Using Assemblies

In this exercise, our goal is to reduce the overall cell count to a reasonable level while retaining a good
cell resolution within the model, especially where the velocity and temperature gradients are higher.
1. Create three individual assemblies (one for the heat sink and the base, the second one for the vent,
and the last one for the fan).
a. Highlight all the pins and the base in the model tree.
b. Right mouse click and select Create then Assembly.
c. Rename the assembly as Heatsink-asy.
d. Double click on the assembly to open the Edit panel.
e. Under the Meshing tab, toggle on the Mesh separately button.
f. Set the slack to the following values:
Table 6.4 Slack Values for Heatsink-asy

Min X 0.005 m Max X 0.005 m
Min Y 0.005 m Max Y 0.005 m
Min Z 0.015 m Max Z 0.005 m
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. Click Update and Done.

h. Following the same procedure above, create two more assemblies; one for vent.1 (name it Vent-
asy) and one for the fan (name it Fan-asy).
i. Use the following tables to assign slack values for Vent-asy and Fan-asy assemblies, respectively.
Table 6.5 Slack Values for Vent-asy

Min Z 0.01 m Max Z 0m
Table 6.6 Slack Values for Fan-asy

Min Z 0m Max Z 0.01 m
2. Put the previously created assemblies into an outer assembly covering all.
a. Highlight all the three assemblies above and click the right mouse button.
b. Select Create assembly.
c. Rename this main assembly HS-vent-fan-asy.
d. Assign the following slack values to the assembly.
Table 6.7 Slack Values for HS-vent-fan-asy


Min Z 0m Max Z 0m

1. Go to Model → Generate Mesh or use the toolbar shortcut ( ) to open the Mesh control panel.
2. In the Mesh control panel, specify a global maximum element size of 0.025 m in all three directions
(Max X size = Max Y size = Max Z size = 0.025).
3. Verify that the Coarse option is selected next to Mesh parameters and change the Max size ratio
from 10 to 5.
4. Make sure that Mesh assemblies separately button is toggled on.
5. Under the Options tab, set the Init element height to 0.003.
6. Click Generate. Visualize the mesh by making plane cuts and surface displays under the Display tab,
especially between the heat sink pins and on the surface of the fan and grille objects. The meshing
panel should look like the one in Figure 6.5 (p. 115) when finished:
Figure 6.5 Mesh control Panel

1. Go to Problem setup → Basic parameters. In the General setup tab, change the Flow regime
to be Turbulent and keep the default selection of Zero equation.
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.
Figure 6.6 Turbulent Flow and Initial Z-Velocity
3. Under Solution settings → Basic settings, set the Number of iterations to 200 (Figure
6.7 (p. 116)).
Figure 6.7 Basic settings Panel
4. Click Accept.

idea to save the model (including the mesh) yourself as well.

1. Add in two monitor points, one to monitor velocity at the center of vent.1, and one to monitor the
temperature at the center of the block.1.
a. Select vent.1 and block.1 from the list and then drag them to the Points branch of the tree.
(Alternatively, one can create monitor points by simply selecting these objects in the model tree,
clicking on the right mouse button and selecting Create and then Monitor point.)
b. Because ANSYS Icepak will by default monitor the temperature at the centroid or center of these
objects, double-click on vent.1 under the monitor Points branch.
c. Select velocity as the variable to monitor and deselect temperature.
d. Accept the change.
2. Go to Solve → Run solution or click on the shortcut button ( ). Start the solver by clicking Start
solution.

To postprocess results for this exercise, create the following object-face and plane-cut views:

Ob- Specifications Description
ject
face.1 Object: all blocks Object-face view of temperature on all the blocks.
(Choose using Ctrl and Shift keys Observations: The view shows the flow of heat
and left mouse button) from the heated block (block1.) to the air-cooled
Show contours heat sink.
Parameters
Contours options: Solid fill/ Smooth
Color levels: Calculated/ Global limits
cut.1 Plane location: Plane cut (x-z) view of the velocity vectors through
Set position: Y plane through center the center of the fan.
Scroll up to about 0.8 Observations: The view shows air flowing from
Show vectors the grill to the fan, passing through the fins of
the heat sink.
Parameters
Color by: Velocity magnitude
face.1 and cut.1 should look similar to Figure 6.8 (p. 118) and Figure 6.9 (p. 119) that follow.
Figure 6.8 face.1 (Temperature Contour -all blocks)
Step 9: Summary
Figure 6.9 cut.1 (Velocity Vectors through Fan)

In this problem, we have modeled a simplified heat pipe using cylindrical solid blocks of orthotropic
conductivity. The exercise also demonstrated the application of copy and mirror features as well as the
use of nested non-conformal meshing using assemblies in ANSYS Icepak.
Chapter 7: Non-Conformal Mesh
7.1. Introduction
This tutorial compares the effects of using a conformal mesh versus a non-conformal mesh in a simple
pin-fin heat sink problem.
• Generate a non-conformal mesh and related parameters such as bounding box, slacks etc.
• Understand the effects of non-conformal mesh on total mesh counts and on results.
• Generate and compare summary reports.
• Apply non-conformal rules and restrictions.
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.

The model consists of a pin-fin heat sink composed of aluminum, which is in contact with a source
dissipating 10 W, as shown in Figure 7.1 (p. 122). The source-heatsink assembly sits in the middle of a
wind tunnel with a wind speed of 1.0 m/s. The ambient temperature is 20°C. The flow regime is turbulent.
The objective of this exercise is to become familiar with the non-conformal meshing methodology and
its application. The solution results of conformal and non-conformal mesh will be examined and com-
pared.
In ANSYS Icepak, assemblies of objects can be meshed separately. A region can be defined around a
particular assembly and this region can be meshed independently of the mesh outside this region. This
allows a fine mesh to be confined in a particular region of interest and it helps to reduce overall mesh
count without sacrificing the accuracy of the results.

Open a new project and name it non-conformal.

• Cabinet
Enter the following start and end locations for the Cabinet.
xS 0.3 m xE 0.7 m
yS 0.5 m yE 0.7 m
zS 0.0 m zE 1.0 m
– Opening on Cabinet Boundaries
Open the Cabinet object panel. In the Properties tab, change Wall type of Min z to Opening.
Click Edit to open the Openings panel. In the Properties tab of the Openings panel, enter 1
m/s for the Z velocity and keep Temperature as ambient (which is 20°C).
– Grille on Cabinet Boundaries
Under the Properties tab of the Cabinet panel, change the wall type of Max z to Grille. Click
Edit to open the Grille panel. In the Properties tab of the Grille panel, change the free area
ratio to 0.8 and leave the other default property specifications.
Figure 7.2 Grille Properties Specifications
• Source
Create a source using the following dimensions:
Object Specification
source.1 xS = 0.48 m xE = 0.52 m Total power: 30 W
Geometry: Rectangular yS = 0.52 m yE = —
Plane: X-Z zS = 0.48 m zE = 0.52 m
• Heat sink
Now, create a heat sink with the following geometrical and physical properties.
Tab Settings
Geometry 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
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).
Figure 7.3 Heat sink Properties
7.6. Step 3: Generate a Conformal Mesh

Generate a conformal mesh for the model.
1. Open the Mesh control panel using Model → Generate mesh.

a. In the Mesh control panel, set the Max element size for X to 0.02 m, for Y to 0.01 m, and for
Z to 0.05 m.
b. Under the Global tab, make sure that Normal is selected next to Mesh parameters.
c. Under the Misc tab, make sure Allow minimum gap changes is checked.
d. Click Generate.
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.

c. In the Set position drop-down list, select Y plane through center.
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.
Figure 7.4 Conformal Mesh, Central Y Plane

a. Deselect the Display mesh option.
b. Click Close to close the Mesh control panel.

Before starting the solver, you first review estimates of the Reynolds and Peclet numbers to check that
the proper flow regime is being modeled.
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.
Go to Solution settings → Basic settings and set the Number of iterations to 300. Go to Ad-
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.

idea to save the model (including the mesh) before the solution. The model can be saved using File
→ Save project.

Start the calculation by clicking on Solve → Run solution. Specify “conformal" as the ID. Click Start
solution to start the solver.

In this step, you will examine the maximum temperature using ANSYS Icepak's summary reporting tool.
Report → Summary report
1. Define a report that will display temperature data for the source and the heat sink.
a. In the Define summary report panel, click New.
b. In the Objects drop-down list, select heatsink.1 and click Accept.
c. In the Value drop-down list, select Temperature.
d. Repeat steps (a) through (c) for source.1.
Step 8: Add an Assembly to the Model
e. Click Write to generate a summary report.
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. Click Done to close the Report summary data panel.

3. Click Close to close the Define summary report panel.
7.11. Step 8: Add an Assembly to the Model

You will now create an assembly out of the source and heat sink objects. The assembly will be meshed
separately from the rest of the model.
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 non-
conformal mesh) and calculate the solution again which is shown in steps 9 through 11.
1. Create an assembly consisting of the source and the heat sink objects.
a. Click the Create assemblies button ( ) to create a new assembly. This creates an assembly node
in the Model manager window under the Model node.
b. 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.
c. Hold down the left mouse button, drag both highlighted items into the assembly.1 node of the
tree, then release the left mouse button.
2. Edit the assembly and define its bounding box.
a. Select the assembly.1 node in the Model tree, and then click the Edit object button ( ) to open
the Assemblies panel.
b. Click the Meshing tab.
c. Turn on the Mesh separately option and enter the Slack parameters shown in Figure 7.5 (p. 128).
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.
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
7.12. Step 9: Generate a Non-conformal Mesh

assembly.1 will be meshed separately when the mesh is generated. The non-conformal mesh will limit
the clustering to a region inside a bounding box slightly larger than the source-heatsink assembly.
1. Generate a non-conformal mesh for the model.

a. In the Mesh control panel, keep the Max element size for X set to 0.02 m, for Y set to 0.01
m, and for Z set to 0.05 m.
b. Under the Global tab, make sure the Mesh assemblies separately option is checked.
c. Click Generate to create the mesh.
Note
Make a note of the number of elements, the minimum face alignment, and the
aspect ratio.

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.
Figure 7.7 Non-conformal Mesh

a. Deselect the Display mesh option.
b. Click Close to close the Mesh control panel.


1. Retain the same Number of iterations (300) in the Basic settings panel.
Step 13: Summary
2. Start the Solution.

a. Specify non-conformal as the solution ID.
b. 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 itera-
tions required for convergence may vary on different computers.

In this step, you will examine the maximum and minimum temperatures of the source and heat sink in
the new version of the model.
Report → Summary report
1. Define a report that displays temperature data for the assembly.

a. Retain the same temperature report of the source and the heat sink, as used in the version without
the assembly.
b. Click Write to generate a summary report.
Note that the maximum temperature is about 35.8° C, representing a temperature rise of
about 15.8° C from the ambient temperature of 20° C. The maximum temperature is very
close to that obtained in the version with conformal mesh.
2. Click Done to close the Report summary data panel.
3. Click Close to close the Define summary report panel.

In this tutorial, you generated both a conformal and a non-conformal mesh for a simple source-heatsink
geometry and compared the two sets of results. The comparison found an approximate 20 percent re-
duction in the number of cells for the non-conformal mesh with a negligible change in the temperature
data.
Chapter 8: Mesh and Model Enhancement Exercise
8.1. Objective
The objective of this exercise is to lead you through the decision making process that's involved in
improving a model. The inferences from the exercise should help you make appropriate modeling
choices during your next thermal modeling project.
8.2. Prerequisites
The trainee should be familiar with:
• ANSYS Icepak modeling objects

• Basics of meshing
• Non-conformal meshing
8.3. Skills Covered

• Choice of thin vs. thick objects
• Basic meshing techniques
• Use of object separation setting
8.4. Training Method Used

A troubleshooting approach is used in this tutorial. A model with potential for improvement is provided.
You will be given 15 minutes to try your hand at improving the model (note: you are not expected to
complete all the improvements in this short time). This will help you familiarize yourself with the issues
associated with the model. Then, an approach for improving the model is delineated in the form of
step-by-step hints. Feel free to explore the software interface, collaborate with another trainee, or ask
the instructor.
8.5. Loading the Model

• Unpack and load the model named meshing-tutorial-start.tzr.
• Rename it to any other name of your choice.
8.6. A 15 Minute Exploration

Without making any changes, the model results in about 750,000 cells. It is possible to reduce this mesh
significantly without compromising accuracy. You are allowed to modify, delete, or add objects as long
as the physics being modeled stays unchanged. You may want to refer to the power and material spe-
cifications to justify model changes. Non-conformal meshing is one of the techniques that will help you
accomplish this task.
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 orient-
ations and locations to identify root causes that result in unnecessary mesh clusters in non-
critical regions. Then modify the model in order to tackle the issues you notice.
8.7. Step-by-Step Approach

• Save the model you have been working on to another name. (You may be revisiting this model to
compare notes with the suggested approach)
• Reload the model you had unpacked earlier (“meshing-tutorial-start").
• Save it to another name of your choice.
• Generate mesh without modifying the model. You will see a mesh count of about 750,000 cells.
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?
Modification 1: Non-Conformal Mesh of the Heat Sink and Components
Figure 8.1 A Mesh Cut Plane View of the Given Model When Meshed Without
Modifications
8.8. Modification 1: Non-Conformal Mesh of the Heat Sink and Compon-

ents
1. Create an assembly containing the heat sink and the components cooled by it (green colored objects).
Name it HS-asy.
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.
Regular non-conformal assembly

a. Activate Mesh separately under the Meshing tab of the Assemblies panel for this assembly (HS-
asy) and specify appropriate slack values (we recommend 1 mm on all sides). While specifying
slack values, make sure that you are not violating any of the rules regarding non-conformal
meshing.
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. Generate the mesh again.

c. Observe the decrease in element count with every modification you make. The mesh count should
be around 315,000 cells.
Zero slack non-conformal assembly

a. Open the HS-asy edit panel and change the slack values on all sides to zero.
b. Generate the mesh again.
c. Display the mesh at some selected planes to observe mesh in the domain.
d. Display the mesh on Mask.1. Note that the mesh fully exists for the plate, even though it is inter-
secting with a face of the assembly.
e. Observe the reduction in the mesh count; the mesh count should be about 260,000 cells.
Note
Zero slack non-conformal assembly resulted in fewer mesh count than the regular non-
conformal assembly intersecting thin conducting plate. This limitation will be resolved
in the next step.
Modification 3: Non-Conformal Mesh for the hi-flux-comps Cluster
8.9. Modification 2: Resolution of Thin Conducting Plate Intersecting

Non-Conformal Region
• Question the choice of using the thin conducting plate object type for the plate object (Mask.1).
– What is the thickness of the mask plate?
– What is the conductivity of the solid material assigned to this plate?
– Find out the thickness and conductivity of the PCB on which the thin plate is lying.
– Based on the above information, do you think that the mask object is a significant spreader of heat
compared to the PCB?
→ The mask is not a significant heat spreader, however it tends to impede heat flow across it.
Hence, we cannot completely ignore it.
→ In fact, there are two mask plates modeled as thin conducting plates in this model (one for each
PCB).
→ Change the plate type of both mask plates to Contact Resistance while maintaining the same
thickness (0.00001 m). This way you maintain the thermal resistance in the normal direction while
ignoring the heat spreading laterally.
• Regenerate the mesh or load the existing one (the mesh is still the same as there is no change in geo-
metry).
• View cut planes of the mesh to see if you have any more unnecessary mesh clusters. Figure 8.2 (p. 137)
shows one such cut plane.
– This time the unwanted grids are from the clusters of components called “hi-flux-comp" (red colored
objects).
Figure 8.2 Mesh Bleeding After 1 Non-Conformal Region
8.10. Modification 3: Non-Conformal Mesh for the hi-flux-comps Cluster

1. Create a non-conformal mesh around the cluster of components called “hi-flux-comps".
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.
• 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.
2. 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.
3. Generate the mesh again.
4. Repeat cut plane viewing. Figure 8.3 (p. 138) shows a cut plane view after creating the two separate
mesh regions.
Figure 8.3 Mesh Bleeding from the Boards
8.11. Modification 4: A Super Assembly...

• The mesh bleeding you see in Figure 8.3 (p. 138) can be tackled by creating a separately meshed assembly
of the entire enclosure object (the blue box). In order to see the effect of zero slack non-conformal as-
semblies, you may want to try meshing the model once with zero slack assembly, and then with slack
values for the non-conformal assembly.
• The resultant mesh cut plane is shown in Figure 8.4 (p. 139).
Modification 4: A Super Assembly...
Figure 8.4 Cut Plane View of Recursive Embedded Mesh
• 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.
Figure 8.5 Separation Warning
– 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?
– Do not accept the suggested change to the separation settings.
8.12. Modification 5: A Simplification Based on Magnitudes of Resist-

ances...
• From the name of the object, one can infer that the warning is regarding an air gap under one of the
components, which is modeled as a thick plate.
• There is a reason for not using contact resistance type plate to model the Airgap.
– Two thin objects cannot overlap. If the Airgap was modeled as contact resistance plate, the under-
lying mask may not be meshed in the region common to the Mask and the Airgap.
→ What is the Mask thickness and conductivity?
→ What is the Airgap thickness and conductivity?
→ The purpose for modeling these two objects is to capture their insulating effects.
→ How does the resistance (thickness/conductivity) of the mask compare to that of the Airgap?
→ Does the mask contribute significantly to the overall (sum) of the two resistances?
→ Can you justify suppressing the mask under the air gap by making the Airgap a contact resistance
plate?
→ When you make the Airgap a contact resistance plate, make sure that the Effective thickness
is the same (1e-4 m).
→ Also make sure the Airgap has higher priority over the Mask object.
• You can do this by editing the plate object and changing the Priority setting under the Info
tab. (Larger priority number means higher priority. Objects with higher priority are listed
lower in the Model manager window).
• Generate the mesh again.
• This time you will see another separation warning about the AL-spreader. Again, do not accept the
changes.
8.13. Modification 6: A Classic Case for Thin Conducting Plate...

• Since a contact resistance plate will not model the in-plane spreading of heat, we can't use it here.
Thin conducting plate models conduction in the normal as well as the planar direction. At the same
time the thin conducting plate will not generate slender cells.
The decrease in thickness due to a thin plate approximation of the Al-spreader is negligible.
• Generate the mesh one more time. You will see the separation warning again - this time about the die
objects which are 0.0004 m.
– These objects are power generating components, which are already thin conducting plates. The
warning is about the width of the packages.
– The surface area of the dies is a critical parameter affecting the temperature prediction for the
component. This cannot be simplified.
– Hence accept the suggested change in separation setting. The resultant mesh count will be signific-
antly less than what we got without any changes to the given model.
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.
Chapter 9: Loss Coefficient for a Hexa-Grille
9.1. Introduction
This tutorial demonstrates how to define trials, run parametric solutions, and post-process the results.
Often, there is a need to calculate the loss coefficient of grilles that have certain hole patterns. The
purpose of the problem is to determine the minor loss coefficient of a grille that has hexagonal holes.
• Define a parameter to optimize the design.

• Define trials.
• Define primary and compound functions that you want to report.
• Calculate parametric solutions.
• Report and plot parametric results.
9.2. Prerequisites
solved or read the tutorial "Finned Heat Sink". Some steps in the setup and solution procedure will not
be shown explicitly.

The model includes a cabinet that is 160 mm in length with inlet and outlet openings at the two ends
(with cross sectional area of 7.363 mm x 12.7 mm), and four symmetry walls at the other sides. The
model also includes a part of the hexa-grille placed at the center of the channel in the streamwise dir-
ection, as shown in Figure 9.1 (p. 144). The grille has one full hexagonal hole at the center and four
quarter hexagonal holes placed around it. This pattern was selected because it forms a periodic region
and is sufficient to calculate the loss coefficient. The solution obtained from this run can be replicated
to form the solution for the entire domain.

1. Copy ICEPAK_ROOT/tutorials/loss-coefficient/loss-coefficient.tzr to your
working directory. Replace ICEPAK_ROOT by the full path name of the directory where ANSYS Icepak
is installed on your computer system.
The File selection panel appears.

4. In the File selection panel, select the packed project file loss-coefficient.tzr and click Open.
The Location for the unpacked project file selection dialog appears.
like to place the packed project file, enter a project name in the New project text field, then click
Unpack.

This tutorial uses an existing model. ANSYS Icepak displays the model in the graphics window, as shown
in Figure 9.2 (p. 145).
Figure 9.2 Loaded Model
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. In the Project text box, enter the name loss-coefficient-new.

2. Click Save.
9.6. Step 3: Define Parameters and Trials

You will first define a parameter and trials according to the parameter. Next, you will define a summary
report, then primary and compound functions to be reported.
1. Define a velocity parameter at the inlet opening in terms of the Reynolds number ( ).
Note
The velocity at the inlet opening in terms of the Reynolds number (), which is cus-
tomarily used in loss-coefficient plots in lieu of velocity, is calculated as = ∗ ,
where the kinematic viscosity ν = 1.5843e-5 kg/m.s, and the hydraulic diameter of the
duct Dh = 9.322e-3 m.
a. 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.
b. Click the Properties tab.
c. Select X Velocity and set the value to $Re*1.5843e-5/9.322e-3.
Step 3: Define Parameters and Trials
d. Click Done to set the properties of the opening. This opens the Param value panel.
e. 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. In the Parameters and optimization panel, make sure Parametric trials and All combinations
are enabled in the Setup tab.
b. 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.
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 Ex-
port 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.
d. Click Done to close the panel.

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. In the Define summary report panel, click New.
b. In the Objects drop-down list, select cabinet_default_side_maxx and click Accept.
c. In the Value drop-downlist, select UX.
d. Repeat steps (a) and (b), then select Pressure in the Value drop-down list.
e. Repeat steps (a) through (d) for cabinet_default_side_minx.
f. Click the Close button to accept the settings and close the panel.
4. Set the parametric trials and define primary and compound functions.
Solve → Run optimization

a. In the Parameters and optimization panel, click the Setup tab.
b. Verify that the Parametric trials and All combinations options are turned on.
c. Click the Functions tab.
d. 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. Under Primary functions, click the New button to open the Define primary function panel.
ii. In the Define primary function panel, enter Pstat_in for the Function name.
iii. Select Report summary from the Function type drop-down list and cabinet_de-
fault_side_minx Pressure from the Item drop-down list and retain the selection of Max.
iv. Click Accept to accept the changes and close the panel.
v. Repeat steps (i) through (iv) for the following three functions:
Function Function type Item Max/Mean

name
Pstat_out Report summary cabinet_de- Max
fault_side_maxx
Pressure
Uave_in Report summary cabinet_de- Mean
fault_side_minx UX
Uave_out Report summary cabinet_de- Mean
fault_side_maxx UX
Important
All function names are case-sensitive.
5. Define five compound functions (Pdyn_in, Pdyn_out, Ptot_in, Ptot_out, and Kfact).
a. Under Compound functions, click the New button to open the Define compound function
panel.
b. In the Define compound function panel, enter Pdyn_in for the Function name.
c. Next to Definition enter 0.5*1.1614*$Uave_in*$Uave_in.
d. Click Accept to accept the changes and close the panel.

e. Repeat steps (a) through (d) for the following four functions:
Function name Definition

Pdyn_out 0.5*1.1614*$Uave_out*$Uave_out
Ptot_in $Pstat_in+$Pdyn_in
Ptot_out $Pstat_out+$Pdyn_out
Kfact ($Ptot_in-$Ptot_out)/$Pdyn_out
6. Click Done to close the Parameters and optimization panel.

For this model, you will generate the mesh in just one step. The resulting mesh will be sufficiently fine
near object faces to resolve the flow physics properly.
Model → Generate Mesh
1. Generate the mesh for the model.

a. Keep all the defaults in the Mesh control panel.
b. Click Generate in the Mesh control panel to generate the mesh.
Note
The mesh display plane is an - plane cut through the center of the cabinet as
shown in Figure 9.3 (p. 154).
Figure 9.3 Mesh on the x-z Plane
3. Deselect the Display mesh option to turn off the mesh display.
4. Click Close to close the Mesh control panel.

1. Confirm that only the flow solution is to be obtained, and the flow regime is set to laminar.

a. Keep the default selection of Flow(velocity/pressure) under Variables solved.
b. Keep the default selection of Laminar for the Flow regime.
c. Click Accept to close the panel.
2. Increase the Number of iterations to 500.

a. Enter 500 in the Number of iterations field.
b. Click Accept in the Basic settings panel.
3. Confirm under-relaxation factors are correct.
Solution settings → Advanced settings
The Advanced solver setup panel opens.

a. Confirm that the Under-relaxation factor for Pressure is 0.7 and for Momentum is 0.3.
b. Click Accept in the Advanced solver setup panel.

the calculation, you will be able to open the project you saved and continue your analysis in a future
ANSYS Icepak session. (If you start the calculation in the current ANSYS Icepak session, ANSYS Icepak will
simply overwrite your project file when it saves the model.)

Start the calculation.
1. Solve → Run optimization
Note
Alternatively, you can click the button in the Model and solve toolbar to display
the Parameters and optimization panel.
2. Make sure Allow fast trials (single .cas file) is unchecked in the Setup tab.
3. Click Run in the Parameters and optimization panel.

As ANSYS Icepak starts performing the trials, the Parametric trials panel opens, displaying all the
function values defined a priori, as well as parameters and running times for each trial. The Parametric
trials can also be opened by selecting Show optimization/param results from the Report menu.
Report → Show optimization/param results
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.
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)
Figure 9.4 Kfact vs Re Plot

In this tutorial, you used the parameterization tool to calculate the loss coefficient of a grille for different
values of Reynolds number (Re). You also defined other functions (e.g., static pressure and velocities at
the inlet and outlet) that were reported for different Reynolds numbers. The results show that as Re
increases, the loss coefficient decreases.
Chapter 10: Inline or Staggered Heat Sink
10.1. Introduction
This tutorial demonstrates how to use the check-box (boolean) parameter control for design variables,
and how to assign primary functions, in order to determine whether an inline or a staggered pin fin
heat sink performs better in a single model. The resulting maximum temperature on the package will
be compared. Non-conformal meshing will also be employed to reduce the cell count, required memory,
and run time. In addition, particle traces passing a non-conformally meshed assembly will be presented
during the post-processing of the results.

• Define a check-box parameter (design variable).
• Define different values for a design variable.
• Run and report parametric trials.
• Clip a plane cut to align it with the sides of a heat sink assembly.
• Display particle traces coming from the fan and the opening.
10.2. Prerequisites
solved or read Tutorial Finned Heat Sink (p. 3). Some steps in the setup and solution procedure will
not be shown explicitly.

The model includes the package assembly, containing a BGA package object (compact conduction
model), inline or staggered assemblies consisting of the respective heat sink objects, PCB object,
spreader plate, a fan at the exit, and an opening at the inlet of the wind tunnel. The model geometry
is shown in Figure 10.1 (p. 158).

1. Copy the file
ICEPAK_ROOT /tutorials/heat_sink/heat_sink2b.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.
2. Start ANSYS Icepak, as described in Section 1.5 of the User's Guide.
Note
When ANSYS Icepak starts, the Welcome to Icepak panel will open automatically.
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.
Unpack.
Note
This tutorial uses an existing model. ANSYS Icepak will display the heat sink model in the
graphics window. To view all components, expand all the assemblies of the model in the
Model manager 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 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.
• In the Project name text box, enter the name heat-sink-new.

• Click Save.
10.6. Step 3: Define Design Variables
Note
For both heat sinks, you will define the HeatSink parameter, which will activate/deactivate
heat sinks parametrically.
1. Define the HeatSink parameter for the Inline heat sink.

a. Select the Inline assembly in the Model manager window, and then click the Edit object button
( ) to open the Assemblies panel.
Step 3: Define Design Variables
b. Right-click the Active check box to open the Active parameter panel.
c. Select ON if variable is equal to this object's name.
d. Enter $HeatSink in the Variable text box.
Caution
Note that all function names are case sensitive.
e. Click Accept in the Active parameter panel to accept the changes and close the panel.
f. Click Update in the Assemblies panel to open the Param value panel.
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. Click Done in the Assemblies panel to close the panel.

2. Define the HeatSink parameter for the Staggered heat sink.
a. Repeat above steps for the Staggered assembly.
Note
You will not have to specify the initial value again.
10.7. Step 4: Define Parametric Runs and Assign Primary Functions

You will first define values for your design variable. Next, you will review parametric trials and define
primary functions to be calculated and reported.
Extra
Alternatively, you can click the button.
1. Define parameter values.

a. In the Parameters and optimization panel, click the Design variables tab.
b. Next to Discrete values, after "Staggered" type in "Inline". Make sure to separate the
two with a space.
c. Click Apply to accept the changes.
Step 4: Define Parametric Runs and Assign Primary Functions
2. Review trials.
a. Click the Trials tab.
b. Make sure that the Order for Staggered is 1, and for Inline is 2.
c. Select tr_HeatSink_Staggered as the Restart ID for the tr_HeatSink_Inline trial as shown in the
image below.
3. Define a primary function.

a. Click the Functions tab.
b. Click the New button in the Primary functions group box.
c. In the Define primary function panel, enter Tmax next to Function name.
d. In the Value drop-down list, select Maximum temperature of objects.
e. In the Object drop-down list, select the 700_BGA_40X40_5peripheral_p1.50 object in the
Package assembly, and click Accept.
f. In the Define primary function panel, click Accept to save the changes and close the panel.
g. Click Done in the Parameters and optimization panel to close the panel.

For this model, you will not generate a mesh in advance. Meshing will be automatically performed for
each design trial during the parametric trials.
Model → Generate Mesh
1. Make sure that the Mesh type is Hexa unstructured.

2. In the Global tab, make sure that the Mesh assemblies separately option is turned on.
3. Keep all other defaults in the Mesh control panel.
4. Click Close in the Mesh control panel to close the panel.

Define basic parameters.
• Set the Number of iterations to 300.

• Click Accept in the Basic settings panel to accept the settings and close the panel.

10.11. Step 8: Define Monitor Points

It is always a good approach to define monitor points before starting to run a simulation. In this model,
a temperature monitor point was already defined by dragging the BGA package object into the Points
node in the Model manager window. A velocity monitor point was also defined by dragging the Xmax
opening object into the Points node and selecting Velocity and unchecking Temperature from the
Modify points panel. In addition to the residual plot, the monitor plot will display temperature at the
center of the BGA package object during the solution process and provide an indication of convergence.

1. Open the Parameters and optimization panel, if it is not already opened.
Note
You can click the button in the Model and solve toolbar.
2. Click the Setup tab, and make sure that options Parametric trials and All combinations are selected.
Deselect Allow fast trials (single .cas file).
3. Click Run in the Parameters and optimization panel, to start the calculations.
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.
Figure 10.2 The Parametric trials Panel

The results from tr_HeatSink_Inline will be examined in this section.
1. In the Orient menu, select Orient negative Z.

2. Display velocity vectors on a plane cut at the exit region of the heat sink.
Post → Plane cut
Extra
You can also open the Plane cut panel by clicking the button.
a. In the Name field, enter the name cut_velocity.

b. In the Set position drop-down list, select Vertical - screen select.
c. Select a point in the graphics window between the fan and the heat sink assembly.
d. Turn on the Show vectors option, and click Parameters to open the Plane cut vectors panel.
e. In the Plane cut vectors panel, in the Color levels group box, select This object from the Calcu-
lated drop-down list.
f. Check Project to plane.
g. Click Done in the Plane cut vectors panel to accept the changes and close the panel.
h. 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. Hold down the Shift key, press and hold down the middle mouse button on the edge of a vector.
b. Drag the plane cut through the model in the graphics display window.
4. Clip the plane cut to align it with the sides of the heat sink assembly.
a. In the Orient menu, first select Orient positive X, then Scale to fit.
b. 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.
c. In the Plane cut panel (that was already opened), select Enable clipping, then click Max Y in the
orange region under Clip to box.
d. Click the top edge of the assembly in the graphics window.
e. In the Plane cut panel, click Min Z in the orange region under Clip to box.
f. Click the left edge of the assembly in the graphics window.
g. In the Plane cut panel, click Max Z in the orange region under Clip to box.
h. Click the right edge of the assembly in the graphics window.
i. Click the Update button.
Note
The graphics window will be updated, as shown in Figure 10.4 (p. 170)
Figure 10.4 Clipped Plane Cut
5. Display particle traces in a forward direction.

a. In the Orient menu, select Isometric view.
b. In the Plane cut panel, unselect Show vectors and Enable clipping and select Show particle
traces.
c. Click Parameters next to Show particle traces to open the Plane cut particles panel.
d. Select Speed from the Variable drop-down list.
e. In the Display options group box, keep the default selection of Uniform, and enter 50.
f. In the Style group box, keep the default selection of Dye trace and select Particles with Radius
2.
g. In the Color levels group box, select This object from the Calculated drop-down list.
h. 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)
Figure 10.5 Forward Particle Traces
6. Display particle traces at the opening (Xmax).

a. In the Orient menu, select Orient negative Z.
b. In the Plane cut panel, deselect Active and click New.
c. In the Name field, enter the name opening-velocity.
d. In the Set position drop-down list, select Vertical - screen select.
e. Select a point in the graphics window near the opening (Xmax). This point will should be around
0.814 on the slider bar.
f. Turn on the Show particle traces option, and click Parameters to open the Plane cut particles
panel.
g. Select Speed from the Variable drop-down list.
h. In the display options group box, keep the default selection of Uniform, and enter 50.
i. In the Style group box, keep the default selection of Dye trace and select Particles with Radius
2.
j. In the Color levels group box, select This object from the Calculated drop-down list.
k. Click Done in the Plane cut particles and Plane cut panels to close the panels and update the
graphics window.
l. In the Orient menu, select Isometric view.
Figure 10.6 Opening particle traces

In this tutorial, you used the optimization tool to determine whether an inline or a staggered pin fin
heat sink performs better in a single model. The resulting maximum temperature on the package was
found to be higher in the case of the staggered heat sink.
Chapter 11: Minimizing Thermal Resistance
11.1. Introduction
Heat sink optimization is crucial in a variety of industrial applications. Usually, the challenge is to min-
imize the thermal resistance (or to maximize the heat transfer) and the amount of material used for the
heat sink. The objective of this tutorial is to minimize the thermal resistance for the big heat sink, while
keeping the maximum temperature in the entire system below 70°C and ensuring that the total mass
of the heat sinks does not exceed 0.326 kg.
• Set up an optimization problem.

• Define design variables.
• Define primary, compound, and objective functions.
11.2. Prerequisites

The model comprises an FR-4 board (FR-4.1) of 20.32 cm × 30.48 cm and 1.59 mm thick with several
components placed on the board (Figure 11.1 (p. 174)). Two grilles are placed at the upstream and
downstream of the board with the free flow area ratios of 60% and 50%, respectively. There are also
two components (block.1.3 and block.1.3.1) dissipating 5 W each.
There is a CPU (block.1) dissipating 50W and a heat sink (heatsink_small) is placed on the top of it.
Between the heat sink and the CPU, there is a thermal interface material (TIM_1) with a thermal con-
ductivity of W/mK. These components and three small power caps (power_cap_1.1, power_cap_1.1.1
and power_cap_1.1.2), dissipating 1 W each, form a non-conformal assembly (hs_assembly_1).
On the other side of the board, there are eight chips, dissipating 20 W each, and a parallel plate heat
sink (heatsink_big) is placed on the top of the chips. Similar to the case of the small heat sink, there
is a thermal interface material (TIM_2.1 and TIM_2.1.1) between the large heat sink and the chips with
the same thermal conductivity. These components together form a non-conformal assembly (hs_as-
sembly_2).

1. Copy ICEPAK_ROOT/tutorials/optimization/optimization.tzr to your working directory.
Replace ICEPAK_ROOT by the full path name of the directory where ANSYS Icepak is installed on
your computer system.

4. In the File selection panel, select the packed project file optimization.tzr and click Open.
Unpack.

This tutorial uses an existing model. ANSYS Icepak will display the model in the graphics window. To
view all components, expand all the assemblies of the model in the Model manager window.
Step 3: Define Design Variables
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).
1. In the Project name text box, enter the name optimization-new.

2. Click Save.
11.6. Step 3: Define Design Variables

The large heat sink needs to be optimized in terms of the number of fins and fin thickness. Therefore,
you will define the following design variables for the large heat sink: fin count (in the range from 2 to
18) and fin thickness (in the range from 0.254 mm to 2.032 mm).
1. Define the finCount and finThick design variables for the heatsink_big and specify their initial
values.
a. Expand the hs_assembly_2 node in the Model manager window.
b. Select the heatsink_big in the Model manager window and click the Edit object button ( )
to open the Heat sinks panel.
c. Click the Properties tab.
d. Under the Fin setup tab, type $finCount next to Count, and press Enter on the keyboard to
open the Param value panel.
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. 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.
g. In the Param value panel, enter 0.762 for the Initial value of finThick, and click Done to close
the panel.
h. Click Done in the Heat sinks panel to close the panel.

2. Specify the constraint values for the design variables.
Extra
Alternatively, you can click the button.
a. Turn on the Optimization option in the Setup tab. Then click on the Design variables tab.
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. Select finCount from the list, then enter 2 for the Min value constraint, 18 for the Max value
constraint.
c. Select Allow only multiples, keep the default value of 1, and click Apply.
d. Select finThick from the list, then enter 0.254 for the Min value constraint, 2.032 for the Max
value constraint, and click Apply.
e. Make sure Allow only multiples is only activated for finCount, not finThick.
f. Click Done to close the Parameters and optimization panel.

For this model, you will not generate a mesh in advance. Meshing will be automatically performed for
each design trial during parametric trials.
Model → Generate Mesh.
1. Make sure that the Mesh type is Mesher-HD and the Mesh assemblies separately option is turned
on.
2. Make sure the Allow minimum gap changes is enabled in the Misc tab.
3. Click Close in the Mesh control panel to close the panel.

1. Keep all the defaults in the Basic parameters panel.

2. Click Accept in the Basic parameters panel to accept the settings and close the panel.
Solution settings → Basic Settings
1. Make sure Number of iterations is 125.

2. Make sure the convergence criteria for Flow is 0.001, and for Energy is 1e-7.
3. Click Accept to close the Basic settings panel.

11.10. Step 7: Define Primary, Compound, and Objective Functions
Note
The objective of this tutorial is to minimize the thermal resistance of the heat sink while
keeping the maximum temperature for the entire system below 70°C and ensuring that the
total mass of the heat sinks does not exceed 0.326 kg. Therefore, you will define the following
primary functions: thermal resistance for the large heat sink (bighsrth), mass of the large
heat sink (bighsms), mass of the small heat sink (smlhsms), and global maximum temper-
ature of 70°C (mxtmp). You will also define a compound function, the total mass of the heat
sinks of 0.326 kg (totalmass). For the objective function, you will minimize the thermal
resistance of the large heat sink (bighsrth).
1. Go to Solve → Run optimization to open the Parameters and optimization panel.

2. In the Functions tab, define four primary functions.
a. Define the thermal resistance function for the large heat sink (bighsrth).
i. Click the New button under Primary functions.
Step 7: Define Primary, Compound, and Objective Functions
ii. In the Define primary function panel, enter bighsrth next to Function name.
iii. In the Function type drop-down list, keep the default selection of Global value.
iv. In the Value drop-down list, select Thermal resistance of heatsink.
v. In the Object drop-down list, select the heatsink_big object under hs_assembly_2, and
click Accept.
vi. In the Define primary function panel, click Accept to save the changes and close the panel.
b. Define the mass function for the large heat sink (bighsms).
i. 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.
c. Define the mass function for the small heat sink (smlhsms).
i. 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.
d. Define a constraint function as the global maximum temperature of 70°C (mxtmp).
i. Click the New button under Primary functions.
ii. In the Define primary function panel, enter mxtmp next to Function name.
iii. In the Function type drop-down list, keep the default selection of Global value.
iv. In the Value drop-down list, keep the default selection of Global maximum temperature.
v. Select Constraint and keep the default selection of Max value.
vi. Enter 70 in the text entry field and click Accept to save the changes and close the panel.
3. Define a compound function.
a. Under Compound functions, click the New button to open the Define compound function
panel.
b. In the Define compound function panel, enter totalmass for the Function name.
c. Next to Definition enter $bighsms+$smlhsms.
d. Select Constraint and keep the default selection of Max value.
e. Enter 0.326 in the text entry field and click Accept to save the changes and close the panel.
4. Define an objective function.
a. In the Parameters and optimization panel, select bighsrth from the Objective function drop-
down list.
b. Keep the default selection of Minimize value.

1. Open the Parameters and optimization panel, if it is not already opened.
Note
Alternatively, you can click the button in the Model and solve toolbar.
2. Set up the optimization process.

a. In the Parameters and optimization panel, click the Setup tab.
b. Verify that the Optimization option is turned on, and keep all the defaults for this option.
c. Deselect Allow fast trials (single .cas file).
Note
Due to the geometry change based on the fin thickness and fin count, the fast
trials option is not possible in this problem.
d. Select Sequential solution of flow and energy equations.
3. Click Run in the Parameters and optimization panel to start the calculations.

As ANSYS Icepak starts calculating solutions for the model, the Optimization run window opens and
ANSYS Icepak displays the function values, design variables, and the running times for each optimization
iteration. In addition, the function values and design variables are plotted versus iteration number, as
shown in Figure 11.2 (p. 182).
Figure 11.2 The Optimization run Panel
Note
Each iteration takes three trials.

In this tutorial, you used the optimization tool to minimize the thermal resistance for the big heat sink.
The results show that ANSYS Icepak predicts the best (optimized) case has a fin count of 18 and a fin
thickness of 0.56 mm. In this case, the maximum temperature for the entire system is determined to
be 69.21°C (with the constraint of 70°C) while the total mass is 0.3245 kg (with the constraint of 0.326
kg). The objective function (thermal resistance) is predicted as 0.2421°C/W.

You can also try to optimize the fin count and the fin thickness of both heat sinks and the free flow
area ratios of the inlet and exit grilles. A sample case may be as follows:
• Design variables
– Fin count for the large heat sink: 2-20
– Fin thickness for the large heat sink: 0.254-2.032mm
– Fin count for the small heat sink: 2-12
– Fin thickness for the small heat sink: 0.254-2.032 mm
– Free flow area ratio of the inlet grille: 30-80%
– Free flow area ratio of the exit grille: 30-80%
• Primary functions
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: 70°C (mxtmp)
• Compound function
– Total mass of the heat sinks: 0.45 kg (totalmass)
• Objective function
– Minimize the large heat sink thermal resistance (bighsrth)
Chapter 12: Radiation Modeling
12.1. Introduction
This tutorial demonstrates how to model radiation in ANSYS Icepak.
In this tutorial, you will learn how to include the effects of radiation in a free convection environment
with surface-to-surface (S2S), discrete ordinates (DO) and ray tracing radiation models.
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.

Radiation heat transfer becomes significant at high temperatures and is typically more important for
natural convection problems as compared to forced convection problems in electronics cooling applic-
ations. ANSYS Icepak provides three different models to solve for radiation effects: surface to surface
(S2S) model, discrete ordinates (DO) model and ray tracing model. This tutorial involves a source with
a heat sink placed on a printed circuit board (PCB) and is being cooled with natural convection. We will
first solve the model without radiation, then use the surface to surface model followed by the discrete
ordinates and the ray tracing models and lastly compare the results of all these four cases.

Open a new project and name it hsink-rad.

1. Open the Cabinet panel by double clicking the Cabinet object in the Model manager window. In
the Geometry tab, enable the Fix values option to make sure the values stay the same as we use
different units. Change all the units from m to mm. Then, input the following dimensions in the Geo-
metry tab of the Cabinet panel (Figure 12.1 (p. 186)).
Figure 12.1 Dimensions of the Cabinet and the Boundary Condition Specifications
2. 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.
3. Click Done to close the Cabinet panel.
4. 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.
5. Create the PCB.
a. First, create a block and rename it as PCB in the Info tab of the Blocks panel.
b. Specify the dimensions of the block in the Geometry tab as shown below in Figure 12.2 (p. 187).
Figure 12.2 Dimensions of the PCB
c. Click Done to close the Blocks panel.

6. Create a new material and assign it to the PCB.
a. Right-click the Model node and select Create object and then Material. A new node called Ma-
terials will open.
b. Expand the Materials node until you reach material.1. Double click material.1 to open the Ma-
terials panel.
c. 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.
d. Click Done to close the Materials panel.
e. In the Model manager window, double click the PCB object we created to open the Blocks
panel again.
f. In the Properties tab of the Blocks panel, pick material.1 from the Solid material drop-down
list.
g. Click Done to close the Blocks panel.
7. Create the heat sink base.
a. Create a new block and rename it as hs-base in the Info tab of the Blocks panel.
Figure 12.3 Dimensions of the hs-base
c. Click Done to close the Blocks panel.

8. Create the fins.
a. Create a new block and rename it as hs-fin.1.1 in the Info tab of the Blocks panel.
Note
The units depicted in Figure 12.7 (p. 192) are in mm and m.
Figure 12.4 Heat Sink Fin Dimensions
c. Leave all the other properties as their default values. Click Done to close the Blocks panel.
d. To complete the creation of the remaining fins we will use a copy procedure.
i. Right click the hs-fin1.1 object in the Model manager window and select Copy. The Copy
block hs-fin.1.1 panel opens.
ii. Set Number of copies to 8.
iii. Check the Translate option and set the X, Y and Z offset to 15, 0, and 0 mm respectively.
iv. Click Apply to close the Copy block hs-fin.1.1 panel and create the new fins.
9. Create a 75W 2D source.
a. Create a source using the Create sources button in the model toolbar.
b. In the Sources panel, specify the geometry and properties of the source according to Figure
12.5 (p. 190).
c. Click Done to close the Sources panel and complete the creation of the model.
Figure 12.5 Source at the Bottom on the Heat Sink
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).
Figure 12.6 Schematic of the Model

In order to generate a fine mesh on the heat sink and the neighboring regions while retaining a
coarser mesh in the remaining part of the model, we create a non-conformal assembly enclosing all
the objects created and specify separate meshing parameters for this assembly.
1. Choose the source (source.1), base of the heat sink (hs-base), and all the fins (hs-fin1.1.x) in the
Model tree together and right mouse click to and select Create and then Assembly.
2. Double click assembly.1 in the model tree to open the Assemblies panel.
a. In the Meshing tab, click on the Mesh separately button, and specify the slack values as well as
the max sizes in each of the coordinate directions for the assembly as depicted in Figure 12.7 (p. 192).
b. This will refine the mesh within the assembly and also prevent the increase in the overall mesh
count by confining the fine mesh to within the assembly object.
Note
The units depicted in Figure 12.7 (p. 192) are in mm and m.
Figure 12.7 Meshing Parameters for assembly.1
c. Click Done to close the Assemblies panel.

3. Once the assembly creation is complete, open the Mesh control panel by pressing the Generate mesh
button.
a. Change the Mesh units to mm.
b. Input the Max element size specifications according to Figure 12.8 (p. 193).
Step 5: Solving the Model Without Radiation
Figure 12.8 Global Mesh Control Parameters
c. Keep all other parameters as their default values.

d. Make sure Allow minimum gap changes is checked under the Misc tab.
e. Press Generate to create the mesh.
f. You can view the mesh using the Cut plane and Surface options available in the Display tab.
g. 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.

Once the model is meshed, we will solve it for different situations, i.e. with radiation off followed by
including the effects of radiation using both the view factor method as well as the discrete ordinates
and ray tracing methods available in ANSYS Icepak 13 or later.
12.8. Step 5: Solving the Model Without Radiation

1. Go to Problem setup → Basic parameters.
a. Under the General setup tab(Figure 12.9 (p. 194))
i. Make sure that solution for both the Flow and Temperature is switched on.
ii. Because this is a natural convection problem turn on the Gravity vector option.
iii. Choose Turbulent under the Flow regime group box and use the default option of Zero
equation.
iv. Make sure that the Radiation option is turned Off.
Figure 12.9 Basic Parameters
b. Under the Defaults tab

i. In the Ambient conditions group box, set the Temperature and the Radiation temp to
40°C.
c. Under the Transient setup tab.
i. Enter a small velocity value for the Y velocity such as 0.01 m/s.
Note
In free convection flow problems, setting a small initial velocity opposite to

the gravity vector direction is suggested.
ii. Retain the defaults for all other settings in the Basic parameters panel.
d. Press Accept to close the Basic parameters panel.
2. Go to Solution settings → Basic settings.
a. Set the Number of iterations to 400
b. Make sure the Flow is 0.001 and the Energy is 1e-7 in the Convergence criteria group box.
c. Click Accept to close the Basic settings panel.
3. Go to Solution settings → Advanced settings.
Step 5: Solving the Model Without Radiation
a. In the Advanced solver setup panel specify the Under-relaxation parameters of 0.7 and 0.3 for
Pressure and Momentum, respectively.
b. Select Double from the precision drop-down list at the bottom of the panel (Figure 12.10 (p. 195)).
Figure 12.10 Solution Settings
c. Keep all other default options in the Advanced solver setup panel.
d. Press Accept to close the Advanced solver setup panel.

12.10. Step 7: Calculate a Solution- No Radiation

1. Go to Solve → Run solution to bring up the Solve panel.
a. Enter norad as the solution ID.
b. Click on Start solution at the bottom of the panel.
c. Once the solution residuals have converged you can post process the results using plane cuts
and object faces. Note the maximum value of temperature for comparison with successive runs
wherein radiative heat transfer will be enabled in the model.
Note
You can check the maximum temperatures of each object by going to Report →
Solution overview → Create.
12.11. Step 8: Surface to Surface (S2S) Radiation Model

a. In the Basic parameters panel, select On in the Radiation group box.
b. Make sure the Surface to surface radiation model is enabled.
c. Click Accept to close the Basic parameters panel.
2. To model radiation effects go to Model → Radiation form factors or use the radiation icon ( ) to
open up the Form factors panel.
a. Under Participating objects, select all objects by clicking All and leave all other settings to their
default values.
b. Press Compute to calculate the view factors.
i. You can display the view factors calculated by clicking each participating object listed under
Display object values.
ii. After reviewing the view factors, select Don't recompute.
iii. The settings for the view factor calculations setup are shown in Figure 12.11 (p. 197).
c. Press Close to close the Form factors panel.
Figure 12.11 Enabling Radiation in ANSYS Icepak Model
3. Go to Solve → Run solution and start the solver with S2S as the solution ID.
4. Once the solution residuals have converged, make note of the maximum temperature.
12.12. Step 9: Discrete Ordinates (DO) Radiation Model

Next, we will run the discrete ordinates radiation model.

a. Enable the Discrete ordinates radiation model option in the Radiation group box.
b. Press Accept to close the Radiation panel.
2. Start the solution again with DO as the solution ID.
12.13. Step 10: Ray Tracing Radiation Model

Next, we will run the ray tracing radiation model.

a. Enable the Ray tracing radiation model option in the Radiation group box.
b. Press Accept to close the Radiation panel.
2. Start the solution again with Ray as the solution ID.

Compare the maximum temperature between the runs where radiative heat transfer was enabled versus
the runs where it was not. You can clearly see that radiation is important in this model and there is a
significant difference in the maximum temperature in the field with and without radiation. Further,
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.
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
Table 12.1 Maximum Source Temperature for Different Models

No radiation 82.59°C
Surface to surface 75.08°C
Discrete ordinates 76.38°C

Ray tracing 75.63°C
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.

In this problem we demonstrated how to model radiation in ANSYS Icepak. We first solved the model
without radiation and then used the surface-to-surface model followed by the discrete ordinates and
ray tracing methods and lastly compared the results of all four cases.
Chapter 13: Transient Simulation
13.1. Introduction
The purpose of this exercise is to demonstrate how to model and post-process transient problems.
• Define a transient problem

• Specify time-dependent parameters for objects
• Group and copy modeling objects
• Examine the results of a transient simulation, including animating results over time
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.

The model involves a natural convection cooled heat sink and four heat sources attached to the bottom
of the heat sink. The power dissipated by each of the four sources varies with time and peaks at 100
W.

1. Create a new project called transient.
2. From Problem setup → Basic parameters, go to the Transient setup tab, select Transient
under the Time variation group box. Then enter the Start and End times as 0 and 20 seconds, re-
spectively.
3. Click on Edit parameters and set the Time step increment to 1 s and the Solution save interval to
1. Click Accept in the Transient parameters panel and then the Basic parameters panel to save the
new time parameters.
Figure 13.1 Setting up the Model as Transient

Construct the model according to the following specifications. The final model is shown in Figure
13.4 (p. 206).
• Cabinet
xS 0.05 m xE 0.35 m
yS 0.1 m yE 0.55 m
zS 0.05 m zE 0.25 m
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
plate.1 xS = 0.1 m xE = 0.3 m Solid material:
Geometry: yS = 0.2 m yE = 0.4 m default
Rectangular zS = 0.12 m (Al-Extruded)
Plane: X-Y Thermal model:
Conducting thick: 10 mm
• Blocks
Object xC yC zC Height Radius IRadius Specification

block.1 0.15 m 0.25 m 0.13 m 0.06 m 0.02m 0.0 Block type:
Geometry: Solid
Cylinder Radius2 IRadius2 Solid material:
Plane: X-Y 0.012m 0.0 default
Nonuniform radi- (Al-Extruded)
us
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 are constant,
and is the time.
source.1 xS = 0.12 m xE = 0.18 m Total power = 100 W
Geometry: Rectangular yS = 0.22 m yE = 0.28 m
Plane: X-Y zS = 0.12 m
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.
Figure 13.2 Defining Transient Power for the Sources
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.
To view the time-dependent power specified for the sources, go to Problem setup → Basic
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.
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).
Figure 13.4 Schematic of the Model

To generate a mesh for this model, go to Model → Generate mesh and specify a global maximum
element size of 0.02 m in the x, y and z directions in the Max element size group box. Across from
Mesh parameters, select Normal and keep the default global mesh settings parameters. Then go to
the Options tab and select Init element height and enter 0.005. Then click Generate to create the
mesh. Once the mesh is generated, display and examine the mesh from the Display tab. Remember to
uncheck the Display mesh option when you are done examining the mesh.
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.

The transient settings for this model were defined at the initial stages of model building. This is required
as assigning transient power to the sources require the problem as transient a priori.
Go to Problem setup → Basic parameters. In the General setup tab, ensure Laminar is set for
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.
Step 8: Generate a Summary Report
Go to Solution settings → Basic settings and click on Reset to examine the estimated Rayleigh
number. Then go to Solution settings → Advanced settings and set the Under-relaxation
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.


Go to Solve → Run solution. In the Results tab, click Write overview of results when finished and
click Start solution.
13.10. Step 8: Generate a Summary Report

Go to Solve menu and select Define report. In the Define summary report panel, enable Specified.
Select All times in the Report time group box. Select New, hold down the Shift key and select all
blocks in the Objects drop down list. Click Accept. Click Write to display the Report summary data
panel shown in Figure 13.6 (p. 208)
Figure 13.6 Define summary report Panel

Results of transient runs can be displayed in still images or animations.
To display still images, you can choose to display at a given time or a given time-step. To do so, after
creating post objects in the same manner as in a steady state run, you can go to Post → Transient
settings or click the transient settings icon ( ) to open the Post-processing time panel. To display
at a given time-step, you can toggle on Time step, and click Forward or Backward to step through
the time steps. To display at a given time, you can toggle on Time value, fill in the time to begin the
display and the time Increment, and select Forward or Backward.
To view these images in this model, create the following post-processing objects:

Object Specifications Description
face.1 Object: all blocks and Observations: The view shows the temperature distribution on
plate.1 the faces of all the blocks and the base plate. The transport of
Show contours/Paramet- thermal energy from the sources to the fins of the heatsink can
ers be clearly observed.

Contours options: Solid
fill
Shading options: Smooth
Color levels: Calcu-
lated/Global limits
Post → Transient set-
tings:
Time step: 1 or Time
value: 0
Forward or Backward
cut.1 Set position: Z plane Observation: The view shows air flowing from one opening to
through the other. Also notice that the velocity distribution changes with
center time.
Show vectors/Parameters
Color by: Velocity mag-
nitude
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.
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).
Figure 13.7 History plot
13.12. Step 10: Examine Transient Results in CFD Post

You can also postprocess results using tools in ANSYS CFD-Post. Go to the Post menu in Icepak and
select Write CFD Post File. Enabling this option writes out a data file (filename.cfd.dat) that can be
loaded into CFD-Post.
To launch CFD Post for a Windows system, click Start>All Programs>ANSYS 14.0>Fluid Dynamics>CFD
Post 14.0 or for a Linux system you can access CFD Post using ~ansys_inc/v140/CFD-Post/bin/cfdpost.
In CFD Post, select Load Results... in the File menu to display the Load Results File dialog box. Select
the filename.cfd.dat file that corresponds to the transient solution.
Step 10: Examine Transient Results in CFD Post
Figure 13.8 Results in CFD Post
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. Go to Insert → Text
b. Enter the text, “Auto Annotation”.
c. In the Definition tab of the Details view, enter “Time”.
d. Enable the Embed Auto Annotation option.
e. In the Type drop-down list, select Timestep.
f. Click Apply.
Figure 13.9 Details of Auto Annotation
2. Create a contour.
a. Go to Insert → Contour and create a new contour named TemperatureContours.
b. 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).
Step 10: Examine Transient Results in CFD Post
Figure 13.10 Details of TemperatureContours
Figure 13.11 TemperatureContours Display
3. Display temperature at different time steps.
a. Click the timestep selector icon ( ) to display the Timestep Selector panel. Double click a
timestep to view the corresponding temperatures. See Figure 13.12 (p. 215) for details.
Step 10: Summary
Figure 13.12 Timestep Selector Panel
Additional options that are available in CFD-Post can be found in "Postprocessing Using ANSYS CFD-
Post".

In this tutorial, you set up and solved a transient model and used the animation technique to examine
the results over time. Results were also examined in CFD-Post.
Chapter 14: Zoom-In Modeling in ANSYS Workbench
14.1. Introduction
This tutorial demonstrates how to create and modify a zoom-in model (system sub-model) in ANSYS
Icepak. You will begin in ANSYS Workbench and drag an Icepak template into the Project Schematic.
An Icepak .tzr file is imported, the model is modified and solved according to the instructions in the
tutorial. The project will also include postprocessing results in CFD-Post.
• Create an ANSYS Icepak analysis in ANSYS Workbench

• Create a zoom-in model from a solved system level model
• Run that model with more detail added
• Merge the detailed system level model back into the system level model
• Postprocess results in CFD-Post
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.

The objective of this exercise is to become familiar with ANSYS Icepak's zoom-in-model capabilities.
Detailed systems can sometimes be solved first with reasonable simplifications, and then have more
detailed sub-models run from boundary conditions created from the region in question. For example,
multiple packages can be simplified as one plate with the total power of all packages. A system level
model can be solved, and a sub-region can be created with the velocities and temperatures from the
system level model and have more detail on the board in question.
In this tutorial, you will run a simplified system level model of a slotted chassis, learn how to create an
ANSYS Icepak zoom-in model, run that model and then merge the detailed section back into the original
system.

1. Start ANSYS Workbench.
Figure 14.2 ANSYS Workbench
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.
3. Drag an Icepak template from the Toolbox into the Project Schematic.
4. Right mouse click the Icepak Setup cell and select Import Icepak Project From .tzr.
5. Select Browse... and the File selection panel appears. Select the packed project file rack.tzr and
click Open.
6. The CAD model appears in the graphics display window. Click the isometric toolbar icon ( ) to display
the isometric view of the model.
Note
Look at the specifications of the different components. The model has 10 pairs of plates
(Figure 14.1 (p. 218)). If you examine any pair of plates, plate.1.x represents the PCB and
plate.2.x represents the components on that PCB. In real life each PCB would have many
components mounted on it. We are simplifying the model by representing the components
with a single plate. The thickness of these plates equals the average height of the components.
All the PCBs have the same configuration and the same components. The total power of the
components in each PCB is 30 W, so each of the plates (plate.2.x) are 30 W.
Save the problem to a new project file. This will allow you to expand on the problem without affecting
the original file.
1. In the Project text box, enter the name rack-new.

2. Click Save.
Note
ANSYS Workbench will close Icepak to save the model, you will need to launch Icepak again
to continue.

For this model, you will generate the mesh in just one step. You will specify object-specific meshing
parameters to ensure that the resulting mesh is sufficiently fine near object faces to resolve the flow
physics properly.
1. Go to Model → Generate Mesh or use the toolbar shortcut ( ) to open the Mesh control panel.
2. In the Mesh control panel, make sure Hexa unstructured is selected as the Mesh type.
3. Set the Max element size for X, Y, and Z to 0.03 m if not already set.
4. Select the Normal option next to Mesh parameters.
5. 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 Object name Parameter Requested Value

Openings All openings Y count 10
Plates All plates Low end height 0.003
High end height 0.003
Block block.3 Y count 4
Note
You can also set mesh parameters by right clicking object in the Model tree and select-
ing Edit mesh parameters.
Figure 14.3 Object Parameters in the Mesh control Panel
6. Press Done to close the Per-object meshing parameters panel.

7. 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.

1. Go to Solution settings → Basic settings and Solution settings → Advanced settings
, and verify that the following values are set for each variable:
2. 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.
3. 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.


1. Go to Solve → Run solution menu and turn on Sequential solution of flow and energy equations
in the General setup tab.
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.

1. After the solution has converged, create the following post processing objects:

face.1 Object: plate2.2 Object-face view of temperature on plate2.2
Show contours/Paramet- Observation(s): Note the min & max temperatures and the
ers temperature distribution.
Contours options: Solid fill
Shading options: Banded
Contour levels:
Level spacing: Fixed/
Number = 20
Calculated: This object
face.2 Object: all fans Objects-face showing the flow pattern.

Show particle Observation(s): Animate the particle traces. If you want to see
traces/Parameters motion from start to end, turn off particles and animate the
Variable: Speed traces.
Display options: Uniform
= 50
Style: Dye trace and
Particles
cut.1 Plane location: Plane cut (x-y) view of the velocity vectors in the z plane.
Set position: Z plane Observation(s): Flow patterns (especially around the plates)
through center
Show vectors
cut.2 Plane location: Plane cut (y-z) view of the velocity vectors in the x plane.
Set position: X plane Observation(s): Flow patterns (especially around the plates)
through center
Show vectors
face.1 and cut.1 should look similar to Figure 14.4 (p. 223) and Figure 14.5 (p. 224).
Figure 14.4 face.1 (Plate2.2 Temperature)
Figure 14.5 cut.1 (Z-Plane Through Center Velocity)
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.
14.11. Step 8: Create a Zoom-In Model

With a solution obtained for the main model, we can now zoom-in around one pair of PCB-components
plates, namely plate.1.2 and plate.2.2.
1. Go to Post → Create zoom-in model. The Zoom-in modeling panel appears. The boundaries for
the zoom-in also appear in the ANSYS Icepak main window as a bold white box. By default this zoom-
in box is coincidental with the cabinet.
2. Resize this box by entering the values shown in Figure 14.6 (p. 225) into the zoom-in window. Be sure
to change Max Y to an outflow and Min Z and Max Z to walls. (Please note that the zoom-in box now
surrounds plate.1.2 and plate.2.2 and includes portions of some on the remaining system level model
objects (Figure 14.7 (p. 226)).) There needs to be one outflow to compensate for slight differences in
flow with a pressure differential. The wall objects are created since the entire face on that side is created
in a solid or on a solid surface.
Step 8: Create a Zoom-In Model
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 ac-
curate selection. The boundaries of the zoom-in model will be displayed in the graphics
window as you update them.
Figure 14.6 The Zoom-in modeling setup Panel
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.
4. 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 re-
ports on the operations to construct the model and creates the profiles in the ANSYS Icepak messages
window.
Figure 14.7 Zoom in Box
14.12. Step 9: Edit the Zoom-in Model

1. Set up a new Icepak template in same ANSYS Workbench project. Then link a Results cell to this Icepak
component. The Results cell should link to the Icepak Solution cell.
2. Right mouse click the Icepak Setup cell and select Import Icepak Project
3. In the file selection dialog, select the zoom-in model called rack-new.zoom_in. (It will be in the same
location as the folder for the system level model.) In the system level model we used a single conducting
Step 9: Edit the Zoom-in Model
thick plate to represent the components. We can now replace the plate.2.2 by the individual compon-
ents.
4. Double click plate.2.2 to open the Plates panel and make the following changes:
Field Value
Info
Name Chip
Geometry
Specify by Start / length
YL 0.05 m
ZL -0.05 m
Properties
Power 3.0 W
5. Create nine additional components in an array.

a. Right mouse click Chip and select Copy.
b. Create two copies of Chip with an Z-offset of -0.065 m.
c. Select and highlight all three Chip plates in the Model tree.
d. 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.
e. View the geometry in isometric view (Shift+I).
f. Delete two of the components to form the pattern shown in Figure 14.8 (p. 228).
Figure 14.8 Schematic of the Completed Zoom-in Model
14.13. Step 10: Mesh the Zoom-In Model

1. Go to Model → Generate mesh, and set the Mesh type to Hexa unstructured and the Mesh
parameters to Coarse.
2. In the Local tab, turn off the Object params.
3. In the Global tab, enter the following global mesh settings:
Table 14.1 Global Settings for Zoom-in Model

Max element size for X: 0.003 m
Max element size for Y: 0.02 m
Max element size for Z: 0.02 m
Min elements in gap 2
Min elements on edge 1
Max size ratio 3
The meshing panel should now look like Figure 14.9 (p. 229).
Step 12: Examine the Zoom-in Results
Figure 14.9 Zoom-in Mesh control Panel
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.
14.14. Step 11: Zoom-In Physical and Numerical Settings

1. Drag and drop the two chips in the corners of the top row (chip.5 and chip2.3) into the Points folder
in the Model tree to monitor the temperature at the centers of these two chips.
2. Delete the monitor point plate.2.2 brought in from the system level model (it no longer exists as an
object).
3. Go to Solution settings → Basic settings to change the maximum number of iterations to 300.
4. Solve the model by selecting Solve → Run solution and by clicking on Start solution under the
General setup tab.
14.15. Step 12: Examine the Zoom-in Results

After the solution has converged, create the following postprocessing objects and compare the results
with the system level models.

ject
face.1 Object: all chips Object-face view of temperature on all chips
Show contours/ Para- Observation(s): Note the min & max temperatures and the
meters temperature distribution.

ject
Contours of: Temperat-
ure
Contours options: Solid
fill
Shading options:
Smooth
Calculated: This object
face.2 Object: side_open- Object-face showing the flow pattern
ing.miny
Show particle traces/ Observation(s): Note the flow pattern on both sides of
Parameters plate1.2 and over the components. Animate the particle
Variable: Speed traces.
Particle options
Start time: 0; End time:
1
Display options: Uni-
form = 100
Style: Dye trace and
Particles
Figure 14.10 (p. 231) shows the two object faces at the same time.
Step 14: Additional Exercise 1
Figure 14.10 face.1 and face.2

If we were to model all the components in the system level model, we could have ended up with a cell
count of about 10 times the size of the zoom-in model. The simplifications at the system-level enabled
us to quickly solve the system level model. The zoom-in model showed us the temperature variation
at the card level, which was essential to identify the correct locations of the hot spots.
14.17. Step 14: Additional Exercise 1

Set up this problem in a Workbench based Icepak project. Then set up another Icepak component in
the same Workbench project schematic and replace the PCB plate with a detailed PCB object and
postprocess the results in CFD Post.
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.
14.18. Step 15: Additional Exercise 2

Additional exercise may be performed to create a non-conformal mesh assembly surrounding the details
of the third PCB in the main model. Then, the results obtained using non-conformal meshed assembly
may be compared to the results obtained using the main model with the conformal mesh and to the
ones from the zoom_in approach with conformal mesh.
1. Save the rack-new.zoom_in model with a new model name such as rack.zoom_in_merge.
2. Delete all the components within the model except all the plates which represents the PCB and the
chips and re-save the model. (This version has all the unnecessary components for the system merge
removed.)
3. Open the main model rack.
4. Save it as rack-merge-NC.
5. Use File → Merge Project to import rack.zoom_in_merge into this model with all the details of
chips.
6. Deactivate the old components residing where the merged components are ( plate.1.2 and plate.2.2).
7. Create a non-conformal assembly containing all the chips and the board. It is suggested a slack value
of 3-5 mm in all directions for the assembly is a good value to start without violating any of the rules.
8. Finally, mesh and run the model with a different solution ID and compare the results to the previously
obtained ones. Verify that the results are very comparable.
Figure 14.11 (p. 233) shows a temperature comparison between the zoom-in model and the system
level model with a non-conformal assembly. While the temperatures are slightly different, the
overall distribution (hot spots) stay the same.
Step 15: Additional Exercise 2
Figure 14.11 Temperature Comparison: Zoom-in vs. System with Non-conformal

assembly
Chapter 15: IDF Import
15.1. Introduction
This tutorial demonstrates the “IDF" import capability of ANSYS Icepak.
• Import IDF files.

• Apply the various options offered in ANSYS Icepak's IDF import capability.
15.2. Prerequisites
solved or read the tutorial "Finned Heat Sink". If you have not, please review Sample Session in the
Icepak User's Guide.

Intermediate Data Format (IDF) is a data exchange specification between ECAD and MCAD for the design
and analysis of printed circuit boards. An IDF CAD model is generated by software such as Mentor
Graphics. Typical IDF models include a board file and a library file. The board file includes board layout
(board dimension and shape, location of the components), and the library file includes component in-
formation (size, power dissipation, junction to case and junction to board thermal resistance, etc.). ANSYS
Icepak's IDF import utility is designed to convert the IDF CAD data into an ANSYS Icepak model auto-
matically. ANSYS Icepak imports the geometry as well as parameters such as power and material property
based on the availability of such information.
This tutorial does not involve generating a mesh, calculating a solution or examining results. These
steps will not be shown in this tutorial.

1. Start ANSYS Icepak, as described in Starting ANSYS Icepak on a Linux System and Starting ANSYS Ice-
pak on a Windows System of the User's Guide.
3. Specify a name for your project.

a. In the Project name text box, enter the name idf-demo.
b. Click Create.

To build the model, you will first import the board layout. The board and the associated library files
have to be chosen at this step.
File → Import → IDF file
Figure 15.1 IDF Import Menu
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)).
Figure 15.2 IDF import Panel - Load files
2. Click Next and go on to the Layout options section (Figure 15.3 (p. 237)). Retain all default settings:
• 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 av-
erage 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 com-
ponents to prisms.
Figure 15.3 IDF import Panel - Layout options
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.
Figure 15.4 IDF import Panel - Component figures
4. Click Next to go to the Component models section (Figure 15.5 (p. 238)).
5. Select Model all components as and keep the default settings. The option Choose specific component
model will be discussed later in the tutorial.
Figure 15.5 IDF import Panel - Component models
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.
Figure 15.6 IDF import Panel - Miscellaneous options
7. Click Finish to complete the import.

8. 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.
Figure 15.7 IDF Imported Model with All Components
15.6. Step 3: Component Filtration Alternatives

1. If Filter by size/power is chosen (Figure 15.8 (p. 240)), the size filter and/or power filter may be specified.
Only those components that are either larger than the specified size filter, or dissipate more than the
specified power filter, are imported. If these fields are ignored, all components are imported.
Figure 15.8 IDF Import Panel - Components filters: Filter by size/power
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 in-
cluded. The Component selection panel contains reference designators for all components.
Step 4: Component Models Alternatives
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:
Figure 15.10 Component selection Panel
15.7. Step 4: Component Models Alternatives

1. The Model all components as option is available through both filtration mechanisms.
2. The Choose specific component model option is available when filtering by component type. ANSYS
Icepak allows the component property to be added if no thermal information is available from the IDF
file (IDF 2.0), or modify properties if it is available (IDF 3.0).
3. Under Choose specific component model, properties of required components can be loaded from
an existing file using the Load data from file option. The format for the file is:
Reference designator Power (W) Rjc (C/W) Rjb (C/W)
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.
Figure 15.11 Set Component Property Using File
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.
Figure 15.12 Manual Selection of Component Models

IDF import capability of ANSYS Icepak was used to import a board level model with all components. It
was observed that the board properties and component properties (where specified) were automatically
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.
Chapter 16: Modeling CAD Geometry
16.1. Introduction
Complex geometries are common in today's electronics cooling applications. Examples include complex
enclosure shapes, heat sink fins, louvers, etc. Proper accounting of the geometry of these objects is
important for accurate prediction of flow and heat transfer. Modeling of these complex geometries is
possible by using the direct CAD modeling feature in ANSYS Icepak. The hex-dominant mesher is used
to create an unstructured mesh for these complex shapes.
This tutorial demonstrates how to use the hex-dominant mesher to create an unstructured mesh for
complex shapes in ANSYS Icepak.
• Use a CAD object and create an unstructured mesh using the hex-dominant mesher.
• Solve for flow and heat transfer in a model.
16.2. Prerequisites
miliar with the interface. If you are not, please review Sample Session in the Icepak User's Guide.

The cabinet contains a heat sink 1 with extruded fins having aerofoil cross section, mounted on a block
with a heat source placed between them. These objects are placed in a wind tunnel setup as shown in
Figure 16.1 (p. 246).
1
The heat sink used for this sample problem was obtained from the company Alpha, www.alphanovatech.com/cindexe.html#w.
Figure 16.1 Wind Tunnel Model with Heatsink Modeled as CAD Block
16.4. Step 1: Creating a New Project


a. In the Project name text box, enter the name shapes.
b. 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.

To build the model, you will first create the CAD block representing the heat sink. You will need to
import the required CAD file into ANSYS Icepak. ANSYS Icepak can import CAD files in step and IGES
formats.
1. Import the IGES/Step file into ANSYS Icepak

a. Go to Model → CAD data.
b. Select Load in the CAD data panel and click on Load IGES/Step file.
c. Select w35-20.stp in the File selection panel and click Open.
d. The CAD model appears in the graphics display window.

2. In the CAD data panel, select the surfaces to be used to create the CAD block.
a. In the Creation mode section of the CAD data panel, ensure Selected is enabled.
b. Select Use CAD surfaces directly.
c. In the Create object section, select Blocks.
d. 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 Fam-
ilies, click None to hide all CAD lines and surfaces.
e. Close the CAD data panel.

3. Resize the default cabinet in the Cabinet panel.
Model → Cabinet
a. In the Cabinet object panel, click the Geometry tab.
b. Under Location, enter the Start/end coordinates shown in Table 16.1: Coordinates for the Cabin-
et (p. 249) :
Important
Note that the dimensions are in mm.
Table 16.1 Coordinates for the Cabinet

xS -100 mm xE 150 mm
yS -5 mm yE 20 mm
zS -25 mm zE 25 mm
c. Click Update to resize the cabinet.

d. 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)).
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. Select Opening from the drop-down menu under Wall type for Min x and Max x.
b. Select Edit to display the Openings object panel for Min x and specify the velocity to be 5 m/s.
c. Press Done in the Openings object panel and then the Cabinet object panel to apply the changes
and close the panels.
5. 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. Click the Edit object button ( ) to open the Blocks panel.
d. Enter the Start/end coordinates for the Prism block as shown in Table 16.2: Coordinates for the
Block (p. 252).
Important
Table 16.2 Coordinates for the Block

xS -30 mm xE 30 mm
yS -5 mm yE 0 mm
zS -25 mm zE 25 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.
f. Click Done to modify the block and close the panel.
6. Create a source between the base block and the heat sink.
a. Click the Create sources button ( ) to create a source.

b. Edit the source Geometry with the Start/end dimensions given in Table 16.3: Coordinates for the
Source (p. 252).
Important
Table 16.3 Coordinates for the Source

Shape Rectangular Plane X-Z
xS -10 mm xE 10 mm
yS 0 yE —
zS 10 mm zE -10 mm
c. Edit the source Properties and specify a Total power of 50.0 Watts.
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
Table 16.4 Coordinates for the Wall

Shape Rectangular Plane X-Z
xS -30 mm xE 30 mm
yS -5 mm yE —
zS -25 mm zE 25 mm
b. Edit the wall Properties to specify the boundary conditions of the wall.
i. Select Heat transfer coefficient from the External conditions drop-down list.
ii. Press Edit to open the Wall thermal conditions panel.
iii. Select Heat transfer coeff in the Thermal conditions group box.
iv. 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.
Figure 16.3 Specifying Boundary Condition for the Wall
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).

1. In order to properly mesh the heat sink, a fine mesh needs to be used in that region. To reduce the
overall mesh count, the finely meshed region should be secluded using a separately meshed assembly.
a. Choose the heat sink (F_4074 or similar name) and source.1 from the Model tree and create
an assembly called assembly.1.
b. The meshing parameters for this assembly are shown in Figure 16.4 (p. 255).
Important
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.
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. Choose assembly.1, block.1 and wall.1 from the Model tree and create assembly.2.
b. The meshing parameters for this assembly are shown in Figure 16.5 (p. 256).
Important
Note
There is a larger max grid size in this assembly compared to assembly.1.

3. Go to Model → Generate mesh.
a. Keep the default selection of Mesher-HD for the Mesh type and input the settings shown in
Figure 16.6 (p. 257) below.
Important
Figure 16.6 Mesh control Panel Inputs
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. Click Generate to create the mesh.

4. 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).
Figure 16.7 Mesh Near Heat Sink
Figure 16.8 Y-Plane View of Mesh

a. In the General Setup tab, make sure that both the flow and the temperature fields are switched
on.
Note
This is a forced convection problem; therefore the natural convection as well as

radiation effects can be ignored.
b. Switch off the Radiation and make sure Gravity vector is unchecked.
c. 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. Press Accept to save the settings and close the panel.

2. 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.
3. Stringent energy convergence criterion is required when the energy equation is solved separately.
Go to Solution settings → Advanced settings.

a. Make sure that the Under-relaxation parameters for Pressure and Momentum are 0.3 and 0.7
respectively.
b. Input the following for Temperature in the Linear solver group box:
i. Choose W from the Type drop-down list.
ii. Enter 1e-6 for the Termination criterion and the Residual reduction tolerance.
c. Change Precision to Double.
Step 5: Save the Model
Figure 16.10 Advanced solver setup Panel
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.

1. Go to Solve → Run solution to display the Solve panel.
a. Enable Sequential solution of flow and energy equations.
b. Click Start solution to start the solver.
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.
Note
plot may not look exactly the same as Figure 16.11 (p. 262).
Figure 16.11 Residuals
c. Click Done in the Solution residuals window to close the panel.

The distribution of the different quantities on the CAD heat sink can be visualized using the object face
option, as in any other ANSYS Icepak object.
1. Click the Object face button ( ) under the Postprocessing toolbar.

a. Choose the CAD block from the Object drop-down list
b. Click on Show contours and then Parameters to open the Object face contours panel.
c. Keep the default selection of Temperature in the Contours of drop-down list.
d. Keep the default selection of Solid fill in the Contours of group box.
e. Select Smooth in the Shading options group box.
f. Keep the default selection of Calculated in the Color levels group box and choose This object
from the drop-down list.
Figure 16.12 Post Object Face Settings for CAD Block
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.
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.
Figure 16.13 Temperature Distribution on the Heat Sink
2. Right click face.1 in the Model tree and deselect Active to deactivate the postprocessing object.
3. Click the Plane cut button ( ) under the Postprocessing toolbar.

a. Select Y plane through center from the Set position drop-down list.
b. Select Show vectors option.
c. 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).
Step 8: Summary
Figure 16.14 Velocity Field Around the Heat Sinks Fins

In this tutorial, you imported a CAD object and set up a problem. You then created an unstructured
mesh using the hex-dominant mesher. This forced convection problem was solved for flow and heat
transfer and the results were examined on object faces and cut planes in the model.
Chapter 17: Trace Layer Import for Printed Circuit Boards
17.1. Introduction
A printed circuit board (PCB) is generally a multi-layered board made of dielectric material and several
layers of copper traces. From the thermal modeling point of view, a PCB may be treated as a homogen-
eous material with bi-directional thermal conductivity, i.e. thermal conductivity value is different in the
normal-to-plane direction than that of the in-plane direction. This approach is reasonable as long as
the trace distribution is more-or-less uniform in any given layer. However, with the continuing challenges
to increase product functionality while decreasing product size, designers are compelled to place more
and more functionality on individual PCB's. As PCB's become more densely populated, their trace layers
are becoming more non-uniform and it is prudent to use locally varying thermal conductivity information
on the board.
PCBs often have large copper spread in the power and ground planes, this along with the presence of
vias (especially thermal vias) can be effectively used by the designer to spread heat from the package.
A detailed conductivity map of the pcb is required to simulate heat transfer, which is possible in Ansys
Icepak using the trace feature.
Conducting a computational heat transfer simulation for each individual layer is costly and impractical
for a system level model. In ANSYS Icepak, it is possible to import trace layout of the board and compute
locally varying orthotropic conductivity (kx, ky, and kz) on the board using a profile mesh size. The sup-
ported file formats are (1) MCM, BRD and TCB files and (created using Cadence, Synopsys, Zuken, and
Mentor), (2) ANF files and (3) ODB++ files.
Ansoftlinks installation and licensing is required to create ANF files to be read by Icepak. Icepak can
read ODB++ files, but an Ansoftlinks license is required. To import MCM/BRD files, Cadence Allegro
must be installed.
In this tutorial, we will show :
• How to import trace layout of a typical PCB in TCB format and solve two sample cases based on the
trace layout information.
• How to use Model layers separately option for better accuracy.
• How to import Gerber format layer and via files.
17.2. Prerequisites

A PCB board, library files and traces are imported to create the model. The model is first solved for
conduction only, without the components and then solved using the actual components with forced
convection.


a. In the Project name text box, enter the name trace-import.
b. Click Create.

To build the model, you will first import the board layout. The board and the associated library files
have to be chosen at this step and the trace file can be imported later.
File → Import → IDF file
1. In the IDF import panel, select the board (A1.bdf ). You can keep the default project name A1, specify
the model directory using Browse and click on Next.
The associated library files are imported automatically.
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.
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.
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.
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.
Figure 17.1 A11 Board Layout
a. Unpack A11.tzr file to your desktop and name the project “A11".
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)).
Figure 17.2 Blocks [BOARD_OUTLINE.1] Panel
ii. Select A1.tcb from the Trace file panel. This process may take a few minutes depending on
the speed of your computer.
iii. 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.
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 Thickness (mm)
Layer 1 0.04
Layer 2 0.45364
Layer 3 0.062
Layer 4 0.467
Layer 5 0.055
Layer 6 0.442
Layer 7 0.045
Figure 17.3 Importing Trace Layout and Editing Layer Information
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.
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.
Figure 17.4 Vias Information
vii. Click Accept to save your 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 Ice-
pak 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.
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)).
Figure 17.5 Displaying Traces on the Board
x. Select color by trace; the board traces are as shown in Figure 17.6 (p. 276).
Figure 17.6 Trace Layout on the PCB with the Color by trace Option
17.6. Conduction Only Model (PCB Without the Components)

Follow these steps for a conduction-only model:

You will generate a mesh for each sample problem. First we will consider a board without any compon-
ents.
1. Make all objects (including the openings) inactive except the BOARD_OUTLINE.1 object.
2. Select the cabinet and select Autoscale from the Edit window to make the size of the board and the
cabinet the same.
3. Go to the Properties tab of the Cabinet object panel, and select Wall from the Min z and Max z drop-
down lists.
4. Press Edit next to Min z to open the Walls object panel.
a. In the Properties tab, select Temperature from the External conditions drop-down list, and
keep the ambient temperature (20°C).
b. Press Done to close the panel.
5. Press Edit next to Max z to open the Walls object panel.
a. In the Properties tab, specify a Heat flux of 50000 W/m2 in the Thermal specification group
box.
Note
The rest of the sides are insulated. The board will be simulated using a conduction-
only model.
6. Press Done to close the Cabinet panel.

7. Go to Model → Generate mesh to open the Mesh control panel.
a. Make sure the Mesh type is Mesher-HD.
b. 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.
c. Keep all other defaults and click Generate.
8. Once the mesh has been created, Close the Mesh control panel.
17.8. Step 2: Set Physical and Numerical Values

a. Since this is a conduction only model, toggle off the Flow option in the General setup tab.
b. Make sure Radiation is off and keep all other default values.
c. Press Accept to close the Basic parameters panel.
a. Keep the default Number of iterations and set the Convergence criteria for Energy to 1e-12.
b. Click Accept to close the panel.
a. Input the following for Temperature in the Linear solver group box:
i. Choose W cycle from the Type drop-down list.
ii. Enter 1e-6 for both the Termination criterion and Residual reduction tolerance.
b. Select Double for the solver Precision.
c. Press Accept to close the Advanced solver setup panel.

Go to Solve → Run solution or click on the shortcut button ( ). Start the solver by clicking Start
solution.

1. Once the model has converged, Activate cut.1 if not already activated.
2. Edit cut.1 and make sure that Point and normal is the Set position.
3. Make sure that PX, PY, PZ are 0, 0, and 0.78232, respectively and the NX, NY, and NZ are 0, 0, and 1,
respectively.
4. Press Done and view the model.
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.
Figure 17.7 Temperature Distribution on the PCB (mid-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 post-
processing 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.
Figure 17.8 K_X Distribution on the PCB (mid-plane)
17.12. PCB With the Actual Components Under Forced Convection

Follow these steps for a model that has components:

1. In order to put the actual components back into the model, highlight all the components under the
Inactive folder and drag them back into the Model folder. Highlight the two wall objects created for
the “conduction only" model and drag them into the Inactive folder.
2. Click on the Cabinet and Autoscale it from the Edit window.
3. If not already defined, assign an X Velocity of -1.5 m/s in the Properties tab of the Openings panel
for the Max x side of the cabinet (the minus sign shows that the flow is in the negative x direction).
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. Open the Mesh control panel and choose X, Y, Z sizes as 9.5, 7, and 0.7 mm respectively.
5. Keep all other defaults and Generate the mesh.
17.14. Step 2: Set Physical and Numerical Values

1. Since we now have forced convection, go to Problem Setup → Basic parameters toggle on
the Flow button. Keep and choose Turbulent and Zero equation for the flow regime and press Accept
to close the panel.
2. Go to Solution settings → Basic settings and make sure the Number of iterations is 300 and
that the Convergence criteria are the same as the last mode, and press Accept to close the panel.
3. Keep the same Advanced settings as the previous case.

Click Solve → Run Solution to display the Solve panel. Enter a different solution id for the forced
convection model (i.e., A11-conv). Enable Sequential solution of flow and energy equations and click
Start solution.

To display contours of temperature on the board, follow the procedures below.
1. Once the model has converged, deactivate cut.1 and go to Post → Object Face.
2. Select BOARD_OUTLINE.1 from the Object drop-down list, and deselect all the options except Max
Z in the Object sides group box.
3. Turn on the show contours and click on Parameters button.
4. Keep the default selection of Temperature.
5. For Color levels, select This object from the drop-down list.
6. Press Done in the Object face contours panel and then the Object face panel to view the postpro-
cessing object.
This shows the temperature distribution at the top of the surface of the board (Figure 17.9 (p. 281)).
There are two hot spots underneath the high heat flux components.
Using the Model Layers Separately Option
Figure 17.9 Top Surface Temperature Distribution: PCB With Imported Traces (100
x 100) in Forced Convection
7. Deactivate the face.1 postprocessing object.
17.17. Using the Model Layers Separately Option

Next we revisit the conduction only model. This time all the metal layers will be modeled separately
and not lumped together in the thickness direction.
1. Go to the Post → Load solution ID.

2. Select the solution ID corresponding to the model which has just the PCB without any components.
3. Deactivate all postprocessing objects if any are active.
4. Display the Board layer and via information panel by selecting Trace layers and vias from the
Geometry tab of the Blocks panel for the BOARD_OUTLINE.1 object.
5. Check the Model layers separately box and press Accept to close the panel.
6. Press Done to close the Blocks panel.
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.
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.
17.19. Additional Exercise 1

Using this model, you can determine the joule/trace heating of the imported traces. This problem is
described in Tutorial "Joule/Trace Heating".
17.20. Additional Exercise 2

Create a model with a detailed package with thermal solder balls. Place it on a board modeled without
and with separate meshing of the layers and check the difference of temperature distribution.
Chapter 18: Joule/Trace Heating
18.1. Introduction
In Tutorial Trace Layer Import for Printed Circuit Boards (p. 267), you learned how to import a trace layout
of a typical PCB using TCB format and also learned how to model the trace layers separately for better
modeling accuracy. In this tutorial, you will learn how to model resistive heating or joule heating of the
imported traces in the PCB.
Since PCB traces have electrical resistance, they will heat up as current flows through them. Modeling
this phenomenon will provide us with an accurate prediction of the temperature distribution in the
PCB, which can be important, for example, in evaluating the performance of the cooling system.
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.

The model in Tutorial Trace Layer Import for Printed Circuit Boards (p. 267) contains imported traces and
will be used in this tutorial. You will determine the joule/trace heating capacity of the traces.

1. Start ANSYS Icepak, as described in Chapter 1 of the User's Guide.
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/tutori-

als/joule-heating/joule-heating.tzr.
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.

This tutorial uses an existing model. Since the traces are already imported in the model, you will work
directly on the Joule heating capability in ANSYS Icepak.
1. Select BOARD_OUTLINE.1 from the Model tree and open the Blocks panel.
a. In the Geometry tab, click on the Edit button next to Model trace heating. The Trace heating
panel opens.
i. In the drop-down list under Layers, select INT1_3. The list below Display traces shows
available traces. You can filter the traces to view by setting an Area filter (the default in
ANSYS Icepak is 20% of the Largest trace area) and clicking the Filter button. In this example,
use an Area filter of 17890 mm2, as this will only show the significant traces.
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.
Figure 18.1 Trace Heating Panel Selection and Options
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. Click Done in the Blocks panel to close the panel and view the model.
2. Select the polygonal trace from the Model tree and open the Blocks panel.
a. 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).
Figure 18.2 Polygonal Trace Block
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. The Materials panel opens.
B. Make sure the Properties tab of the Materials panel looks like Figure 18.3 (p. 287).
C. Press Done to close the Materials panel.
Figure 18.3 Trace Materials Panel Properties Tab
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. 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.
B. For the second boundary condition, set Side to side42, Boundary type to voltage, and
the Voltage to 0 V.
Figure 18.4 Boundary conditions for the Trace Block
Note
Current conservation needs to be manually inspected by the user.
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.

1. Create a non-conformal assembly for the trace.
a. Right click the BOARD_OUTLINE.1.layer-3-trace-1_1724 object and go to Create and
then Assembly.
b. Double click the assembly you created to open the Assemblies panel.
i. In the Meshing tab, select Mesh separately and input the Slack settings, Mesh type, Max
element size, and Min gap settings as shown in Figure 18.6 (p. 290).
Figure 18.6 Mesh Settings for the Trace Board
Note
Ensure Mesh type is Mesher-HD.

a. Make sure the Mesh type is Mesher-HD.
b. Keep the global settings under the Max element size group box as 9, 5, and 0.75 mm, for X, Y,
and Z respectively.
c. Set the Minimum gap as 0.75, 0.45, and 0.035 mm for X, Y, and Z, respectively.
d. Generate the mesh.
e. Check the mesh quality for the trace and the overall model from the Display and Quality tabs.

1. Double click the cabinet_default_side_maxx object in the Model tree to open the Openings
panel.
a. In the Properties tab, make sure the X Velocity is -1.5 m/s.

a. 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.
b. Press Accept to close the panel.
a. Make sure the Convergence criteria for Flow is 0.001.
b. Set the Number of iterations to 200 and the Convergence criteria for Energy and Joule heating
to 1e-8.
c. Press Accept to close the panel.
i. Choose W cycle from the Type drop-down list.
b. Make sure the Precision for the solver is Double.
c. Press Accept to close the Advanced solver setup panel.

File → Save Project

1. Click Solve → Run Solution.
2. Click Start solution.

Once the model has converged, create an object face.
1. Select the trace and show the temperature contours.

a. Go to Post → Object face.
b. In the Object drop-down list, select the trace (BOARD_OUTLINE.1.layer-3-trace-1_1724).
c. Select Show contours and click Parameters. In the Object face contours panel, select Temper-
ature in the Contours of drop-down list and select This object next to Calculated in the Color
levels group box. Click Apply.
d. Observe the trend of the temperature contour and how it varies from one side to other, and
compare the maximum temperature for the cases with and without trace modeling (Figure
18.7 (p. 292)).
Figure 18.7 Trace Temperature Contours with Forced Convection
2. Now plot the electric potential of the same trace, Figure 18.8 (p. 293).
Figure 18.8 Trace Electric Potential Contours with Forced Convection
a. Click on Parameters to open the Object face contours panel.

b. Select Electric Potential from the Contours of drop-down list and press Apply.
c. Observe the contours.
• Do you observe any similarity between the temperature and the electric potential contours?
• The temperature contours are closely related to the electric potential contours, which is a
direct result of joule heating of the trace.
d. Press Done in the Object face contours and Object face panels to close the panels.

Tutorial Trace Layer Import for Printed Circuit Boards (p. 267) is utilized to model the joule heating capab-
ility of a trace.
Chapter 19: Microelectronics Packages - Compact models
19.1. Introduction
This tutorial is a case study of a board design. A card supplier is making two package type changes to
an existing commercial board. The objective of the thermal simulation project is to see if the selected
new packages are likely to function without overheating. In the event of over heating, what kind of
thermal management should be recommended?
• Perform a board level simulation with appropriate package models.

• Determine if the selected new packages can function without overheating.
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.

A designer is to select packages for a new design at the drawing board level. Available information
about the board and packages is given. Determine cooling solutions in the event there is overheating.

1. Copy the file ICEPAK_ROOT/tutorials/compact-package/compact-package-model-
ing.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.
4. In the File selection panel, select the packed project file compact-package-modeling.tzr and
click Open.
like to place the packed project file, enter a project name (i.e., test-1) in the New project text field
then click Unpack.

This tutorial uses an existing model. ANSYS Icepak will display the model in the graphics window as
shown in Figure 19.2 (p. 297). Available information about the board and packages is shown in
Table 19.1: Available Details for Objects in the Model (p. 297) and Table 19.2: Available Information for 400
PBGA (p. 298).
Figure 19.2 Layout of the board to be analyzed
Table 19.1 Available Details for Objects in the Model

Object # of Occur- Available information Power (w)
rences in
model
PCB 1 1.6 mm thick, FR4 Material, six 1 oz. lay- 0
ers of Copper, 30% coverage for all lay-
ers
Heat Spreader for TO-220 pack- 3 Extruded Aluminum 0
ages
TO-220 Packages 9 1.5
= 2.5° C/W
DIP 6 None 0.5
400 PBGA (new package type to 6 See Table 19.2: Available Information for 2.0
the existing board) 400 PBGA
232 PQFP (new package type to 2 232 leads, 40 mm X 40 mm Footprint, 2 3.5
the existing board) mm height
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.
Table 19.2 Available Information for 400 PBGA

Feature Size (mm) Material/Con- Other info Where to input this
ductivity (W/mK) info?
Overall package 26 x 26 x 2.15 Dimensions tab
Mold compound 0.8 Die/Mold tab
Die 18 x 18 x 0.4 Silicon material Die/Mold tab
Die Flag 18 x 18 x 0.035 80.0 (effective) Die/Mold tab
(equivalent)
Die Attach 0.05 mm thick Not mentioned Die/Mold tab
Substrate 0.4 mm thick FR4 Substrate tab
Substrate traces 0.035 mm thick Copper 4 layers, top and Substrate tab
bottom 30% cover-
age intermediate
layers are 100%
(plane layers)
Vias Unknown Not mentioned Number of vias un- Substrate tab (use 0
known for vias)
Solder Balls Standard Solder 20 x 20 count, full Solder tab
array
Wire Bonds Not mentioned Usually Gold Die/Mold tab
1. Create the PCB
Create a PCB object by clicking on the Create printed circuit boards button ( ). Then edit the
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 pcb.1 XZ 0.0 — 0.0 — 0.0— 0.25— NA— 0.2
a. Go to the Properties tab. Enter the PCB thickness of 1.6 mm for Substrate thickness.
b. Change the default unit from micron to Cu-oz/ft2 for high and low surface thickness and for in-
ternal 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).
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. Deactivate the block named “PCB".

4. 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.
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.
Figure 19.4 Window Selecting Multiple Objects for Simultaneous Edit
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. Select Network for the Block type.
B. Keep the default selection of Two Resistor for the Network type.
C. 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.
Note
Zero resistance means that there would not be any link and the res-
istance values are infinite.
D. Input 1.5 W for the Junction power.
Figure 19.5 TO-220 Properties Tab
iii. Click Done to finish the operation.

b. DIP type packages
i. As we did before for the TO_220 objects, select all the DIP objects and simultaneously edit
them.
ii. Use default solid material (any material will work because we are not interested in DIP tem-
perature).
A. Input 0.5 W in the Total Power field.
B. Click Done
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 simula-

tion with the available power information than to obtain the information
from the supplier. In this context the purpose of the DIP package mod-
eling 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.
1
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.
Figure 19.6 Package Search Procedure
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.
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 op-
tions 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 pack-
age.
iv. 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.
v. Use all other defaults under Die/Mold tab. Click Done to close the tab.
vi. 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 Θjc and Θjb 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. Select Network as the Block type and Two resistor as the Network type.
B. Set the board side as Min Y.
2
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.
C. Input the estimated Θjc (1.4 C/W) and Θjb (6.75 C/W) values in the Rjc and Rjb fields
respectively.
D. Input a Junction power of 2.0 W.
E. Click Done to finish.
ii. 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.
iii. Press Edit for the Min x side to open the Openings panel.
iv. In the Properties tab of the Openings panel, assign an X velocity of 1 m/s.
v. Click Done to close the Openings panel.
vi. The Max x side opening should have the default settings (free opening).
vii. All other cabinet boundaries should be Default.
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.

1. Click the mesh icon .
a. Make sure Hexa unstructured is selected as the Mesh type and Normal is selected for Mesh
parameters.
b. Click Generate to create the mesh.
Figure 19.7 Mesh control panel
c. Evaluate your mesh from the Display and Quality tabs.

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 non-
conformal assemblies, it is possible to reduce the number of elements in the mesh significantly. Display
and compare the conformal and non-conformal meshes.

Let us solve the board model with a 1 m/s inlet velocity.
1. Go to Problem setup → Basic parameters and set the Flow regime to Turbulent in the
General setup tab.
Press Accept to close the panel.
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
to 200 in the Basic settings panel and close the panel. Then go to Solution settings → Ad-
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.

Save the model after the model building and meshing is complete.

1. Define point monitors of temperature for 232-Lead_PQFP package and DIP objects. A point monitor
will be created to monitor the temperature change with iterations (Figure 19.8 (p. 308)).
Figure 19.8 Monitor Point Definition
2. Go to Solve → Run solution and enable Sequential solution of flow and energy equations.
Figure 19.9 Solve panel

First we would like to get an idea of the general temperature distribution pattern on the board.
1. Create temperature contours of the PCB by clicking the Object face icon ( ), selecting Show contours,
clicking Parameters and selecting This object for the Calculated drop-down list.
• Probe temperatures values at desired location after clicking on probe icon ( ).

• Note the higher temperatures in the parts of the PCB under the PQFP packages.
2. 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.
3. 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?
• Are the heat spreaders too close? If so, the air flowing between the spreaders will overheat prevent-
ing 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.

In this tutorial, you performed a board level simulation and determined cooling solutions in the event
there is overheating.

Post-processing showed that the components of 400-PBGA are the most critical object since they are
the hottest. Here are some cooling ideas to set up and perform ANSYS Icepak simulations:
What if...
1. The flow is in the negative X direction?

2. The flow is in the negative X direction, and by judicious use of flow resistances, more flow is diverted
toward the PBGAs (for the same overall flow rate)?
3. The bottom side of the PCB is not dissipating any heat as a result of lying on domain boundary. On
the other hand, there seem to be plenty of space above the board. The main reason for the headroom
above the PCB is the height of the spreader blocks. While there is room to move up the spreader by
a little bit, more room can be gained if the spreader is longer in the X direction but shorter in Y height.
What if both sides of the PCB are exposed to airflow by moving it up?
4. A heatsink is mounted on the PBGA blocks? Will it be possible to use a heatsink in contact with all
PBGAs? Are there any practical issues?
Chapter 20: Multi-Level Meshing
20.1. Objective
The objective of this exercise is to provide a means to improving the mesh resolution and optimizing
the mesh count of a model consisting of CAD objects using the multi-level meshing technique. The
procedure from this exercise should help you make appropriate modeling and meshing choices during
your thermal modeling project.
20.2. Prerequisites
The trainee should be familiar with:
• ANSYS Icepak modeling objects

• Basics of meshing
20.3. Skills Covered

• Basic meshing techniques
• Multi-level meshing
• Uniform mesh parameters option
20.4. Training Method Used

A model with potential for improvement is provided. Then, an approach for improving the model is
presented. Feel free to explore the software interface, collaborate with another trainee, or ask a Tech-
nical Services Engineer.
20.5. Loading the Model

• Unpack and load the model named “HangingNode.tzr"
• Rename it to any other name of your choice.
20.6. Step-by-Step Approach

Without making any changes, the model results in about 650000 finite volume cells. Please note that
this mesh count has been obtained making use of the non-conformal meshing technique that allows
for localized fine meshing, thus eliminating mesh bleeding. However, this mesh does not fully resolve
the fine-level geometric features of the CAD objects. It is possible to further reduce the mesh count
and improve mesh resolution on and around the CAD objects using the multi-level meshing technique.
This procedure starts with a coarse background mesh and resolves fine level features through a series
of successive mesh refinements. It is possible to reduce the mesh count to approximately 500000 and
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.
Step-by-Step Approach
Figure 20.1 Mesh of Flow Guide Without Multi-Level Meshing
Figure 20.2 Mesh of Sheetmetal_HS Without Multi-Level Meshing
20.7. Modification 1: Multi-Level Meshing of the Fan_Guide

• In the Meshing tab of the fan_guide.1 assembly, retain the slack and minimum gap values. However,
change the Max element size values to 4.0 mm.
• Toggle on Set uniform mesh params.
• In the Multi-level tab, toggle on Allow multi-level meshing and set Max Levels to 2.
• Keep the default selection of Proximity and Curvature.
Modification 2: Multi-Level Mesh of the Sheetmetal_hs_assy.1
20.8. Modification 2: Multi-Level Mesh of the Sheetmetal_hs_assy.1

• In the Meshing tab of the Sheetmetal_hs_assy.1, retain the slack and minimum gap values.
However, change the Max element size values to 3.5 mm.
• Toggle on Set uniform mesh params.
• In the Multi-level tab, toggle on Allow multi-level meshing and keep Max Levels as 2.
• Keep the default selection of Proximity and Curvature.
• Enter a value of 1 for Mesh buffer layers.
20.9. Generate a Mesh

• Generate a mesh with the modifications using the same settings as before.
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.
Figure 20.3 Flow_Guide Mesh
Figure 20.4 Sheetmetal Heatsink Mesh
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.
Chapter 21: Characterizing a BGA-package by Utilizing ECAD Files
21.1. Introduction
In Tutorials "Trace Layer Import for Printed Circuit Boards" and "Joule/Trace Heating" you learned how
to import trace layouts for a PCB. In this tutorial, you will learn how to import trace layouts on a BGA
package substrate by using TCB files.
• Import trace layout of a BGA package substrate in TCB format.

• Display traces using the Color by trace option.
• Plot temperature contours on the wirebonds.
• Determine junction-to-case resistance for the package.
21.2. Prerequisites
solved or read the tutorial "Finned Heat Sink" of this guide.

In this tutorial, you will see how to determine temperature profiles on the wirebonds of a BGA package
and junction-to-case resistance.

3. Specify a name for your project (i.e., BGA-package) and click Create.

To build the model, you will change the units, create the PCB, import the traces and resize the cabinet
to its proper size. Then you will create a wall object.
1. Change the unit of length to mm.
Edit → Preferences
a. In the Preferences panel, click on Units, under the Defaults node. In the Category box, scroll
down and select Length, and under Units, select mm.
b. Click Set as default, Set all to defaults and then This project.
2. Create the package object.
a. Click on the packages object button ( ) in the objects toolbar.

b. In the Packages panel, click the Dimensions tab and select ASCII TCB from the Import ECAD
file drop-down list.
Figure 21.1 The Packages Panel (Dimensions Tab)
c. Select block_1.tcb in the Trace file panel and click Open.
Note
block_1.tcb can be found in the installation directory at ICEPAK_ROOT/tu-

torials/BGA-package/block_1.tcb.
d. Keep the numbers for the layers and vias and click Accept in the Board layer and via information
panel.
e. Click on the Die/Mold tab and assign a die Power of 0.5 W.
f. Click Done.
g. 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.
Note
Click the Scale to fit icon ( ) to refocus your model.
h. Right click on the package object in the object tree, choose Traces → Color by trace to display
the traces.
Figure 21.2 Display of Traces
As can be seen in Figure 21.2 (p. 323), the wirebonds are lumped into polygonal plates by
ANSYS Icepak.
i. Change the cabinet zS to -1.2 mm.
j. Create a PCB object and input the following in the Geometry tab:
Plane X-Y Specify by Start / end

xS -7.03 mm xE 7.03 mm
yS -7.03 mm yE 7.03 mm
zS -1.2 mm zE —
k. In the Properties tab, set the substrate thickness as 0.8 mm, then enter the following Cu percent-
ages for the layers:
Figure 21.3 Properties Tab of the Printed Circuit Boards Panel
l. Click on Update. Note that the thermal conductivity information (plane and normal) for the PCB
is updated.
m. Press Done to close the panel.
n. Create a wall object and align it with the min-z side of the cabinet and Rename it as Bottom.
o. Edit the wall object and insulate it by keeping the heat flux as zero in the Properties tab.
p. 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 well-
known correlation in the literature, (Incropera et. al 1). In order to do that, you can follow the
procedure in Figure 21.4 (p. 325).
1
Frank Incropera and David DeWitt, Fundamentals of Heat and Mass Transfer, John Wiley & Sons, Inc., New York, 1981.
Figure 21.4 Determining Heat Transfer Coefficient on the Top Wall

1. Click the Generate mesh button ( ).
2. In the Mesh control panel, enter 0.5 mm, 0.5 mm, and 0.14 mm for the Max element size for x, y,
and z, respectively. Change the Minimum gap values to 0.05 mm, 0.05 mm, and 0.01 mm for x, y and
z, respectively. In the Misc tab, unselect Allow minimum gap changes and click Change value and
mesh in the Minimum separation panels.
Note
Ensure that Mesh type is Mesher-HD.
3. Click Generate.
Figure 21.5 Mesh control Panel
4. Click Close to close the panel once you have created the mesh.

a. Uncheck Flow in the General setup tab.
b. Turn off the radiation and click Accept to close the panel.
a. Change the Number of iterations to 25 and the Convergence criteria for Energy to 1e-15.
b. Click Accept to close the panel.
i. Choose W from the Type drop-down list.
b. In the Precision drop-down list, select Double.
c. Click Accept to save your settings and close the panel.


Go to Solve → Run solution. Click Start solution.

1. When the model converges, plot the temperatures contours on the wirebond and view the variation/sym-
metry of the temperature profiles.
a. Go to Post → Object face and choose the wirebonds under the package object.
Figure 21.6 Object face Panel
b. Select Show contours and click Parameters.

c. Select This object from the Calculated drop-down list.
d. Press Done in the Object face contours and Object face panels to close the panels and view
the temperature contours.
Figure 21.7 Temperature Contours on the Wirebonds (Top View)
2. Go to the Report → Summary report and click on New twice.

a. Choose Source_DIE1 under the package object for the first object and the Top wall for the second
object.
b. Keep the default selection of Temperature under Value for both.
c. Press Write to create the Summary report.
Max die and max top wall temperatures are determined as 142.0 and 129.9°C, respectively. Note
that the top wall represents the case for the package. Therefore, junction-to-case resistance for
this package is determined as:
Step 8: Summary

−
= (21–1)
Where is the die power (0.5 W in this case). Therefore,
=
−
= ° (21–2)

In this tutorial, you learned how to import trace layouts for a PCB on a BGA package substrate by using
a TCB file.
Chapter 22: Zero Slack with Non-Conformal Meshing
22.1. Introduction
This tutorial compares the mesh of a non-conformal assembly with and without slack values around a
heat sink, package and board. The zero slack scenario will be solved and the number of iterations, and
temperature distribution on objects in the model will be performed.
In this tutorial you will learn how to use the zero slack capability in ANSYS Icepak.
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.

The model consists of a detailed heat sink, a BGA package, a block with traces and fluid blocks. The
model setup is shown in Figure 22.1 (p. 332).
Figure 22.1 Problem Schematic
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.
Step 4: Import Traces

1. Copy the file ICEPAK_ROOT/tutorials/ZeroSlack/ZeroSlack_Tut.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.

4. In the File selection panel, select the packed project file ZeroSlack_Tut.tzr and click Open.
like to place the unpacked project file, enter a project name (e.g.0–slack) in the New project text field
then click Unpack.
22.5. Step 2: Default Units

Make sure the default unit of length is mm.
Edit → Preferences
1. In the Preferences panel, click on Units under the Defaults node. In the Category box, scroll down
and select Length, and under Units, make sure mm has an asterisk next to it. If there is no asterisk
next to mm:
a. Select mm from the Units box.
b. Click Set as default.
2. Click Set all to defaults and click This project.

This tutorial uses an existing model. The model contains existing package, board and heatsink assemblies.
22.7. Step 4: Import Traces

1. In the model tree, expand the Board assembly to display the pcb object if it is not already visible. Right
click pcb in the Model manager window and click Edit to display the Blocks panel.
2. In the Geometry tab, select ASCII TCB from the Import ECAD file drop-down list.
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.
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 inform-
ation panel. Enter the layer thickness as shown in the table below.
Layer Thickness (mm)

Layer 1 0.04
Layer 2 0.45364
Layer 3 0.062
Layer 4 0.467
Layer 5 0.055
Layer 6 0.442
Layer 7 0.045
5. By default, layers are lumped for each sub-grid, therefore, the Model layers separately option is off
and will need to be enabled.
a. Click Accept to close the Board layer and via information panel.
b. Then click Edit next to Trace layers and vias in the Blocks panel to reopen the Board layer and
via information panel.
c. The Model layers separately option can now be enabled.
6. The via information is imported automatically, so keep the default settings.
7. 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. Click Done to close the Blocks panel.
22.8. Step 5: Add Slack Values

You will add slack values to the heat sink assembly.
Note
Non-conformal assemblies are used to reduce mesh count in models and to improve mesh
quality.
1. Set the slack values for the heat sink assembly as shown in the figure below.
Step 6: Generate Mesh (with Slack Values)
22.9. Step 6: Generate Mesh (with Slack Values)

You will generate a mesh for the heatsink assembly with slack values.

2. Make sure that the Min elements in gap is 2, the Min elements on edge is 1, and the Max size ratio
is 3.
3. Go to the Local tab and click Edit next to Object params. You will see the following requested values
in the Per-object meshing parameters panel (scroll down to see the inside ratios):
Table 22.1 Object Parameters

Object type Object name Parameter Requested
block pcb X count 25
Z count 5
assembly heatsink.1 all inside ratios 2
assembly board all inside ratios 2
assembly package all inside ratios 2
4. Press Done to close the Per-object meshing parameters panel.

5. Keep all other settings as default and click Generate.
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 as-
semblies. Moreover, mesh bleeding from the meshing plates extends beyond the board
because of the slack values.
22.10. Step 7: Zero Slack

Next, we will consider a board with non-conformal meshing with zero slack values.
Non-conformal assemblies with zero slack help in resolving specific objects without extending the mesh
to the rest of the cabinet. Also, zero slack non-conformal assemblies remove certain limitations that are
present with regular non-conformal assemblies like intersections with other non-conformal assemblies.
In this tutorial, the use of zero slack non-conformal assemblies allows us to have a separate non-con-
formal assembly for the package and to accurately resolve the mesh.
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.
2. In addition, enable Mesh separately in the package and board assemblies (do not change any other
values in these assemblies).
22.11. Step 8: Generate Mesh (with Zero Slack)

Generate a mesh with the same global mesh settings as in Step 6: Generate Mesh (with Slack Values) (p. 335)
so that you can compare the mesh count. Observe that the mesh count is significantly less than that
of the mesh with slack values.

1. In the model tree, go to Solution settings → Basic settings and Solution settings →
Advanced settings, and verify that the following values are set:
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.


Go to Solve → Run solution. Click Start solution.

After the solution has converged, create the following post processing objects:

cut.1 Set position: Y plane through Plane cut (x-z) view of the velocity
center vectors in the y plane.
Show vectors
face.1 Object: pcb Object-face view of temperature
on pcb
Show contours / Parameters Note the min & max temperatures
Calculated: This object and the temperature distribution.
face.2 Object: pcb Object-face showing the conduct-
Show contours / Parameters ivity, K_X.
Contours of : K_X

Zero slack is a feature in ANSYS Icepak that alleviates most restrictions encountered while using the
original non-conformal assemblies. Zero slack non-conformal assemblies not only reduces mesh count
further than original non-conformal assemblies but also allow the user to mesh specific objects separately.
For example in this model, the zero slack capability allowed meshing of the package object separately.
Chapter 23: ANSYS Icepak - ANSYS Workbench IntegrationTutorial
23.1. Introduction
This tutorial demonstrates how to create and solve an ANSYS Icepak analysis in ANSYS Workbench. You
will model a geometry using the direct CAD modeling feature in ANSYS Icepak and create a non-con-
formal mesh for the complex shapes. The project will also include postprocessing the results in ANSYS
CFD-Post and performing a static structural analysis.
• Create an ANSYS Icepak analysis in ANSYS Workbench.

• Postprocess results in ANSYS CFD-Post.
• Solve a project and transfer to ANSYS Mechanical for further analysis.
23.2. Prerequisites
This tutorial assumes that you have little experience with ANSYS Workbench and so each step will be
explicitly described.

The graphics board contains a heat sink with extruded fins having aerofoil cross section, a PCB, capacitors,
memory cards and ports. These objects are placed in a setup as shown in the figure below.
Figure 23.1 Problem Schematic

1. Start ANSYS Workbench.
Note
When ANSYS Workbench starts, the Toolbox and Project Schematic are displayed.

1. Add a Geometry template by dragging the template from the Toolbar under the Component Systems
node into the Project Schematic. Perform a right mouse click on the Geometry cell (A2) and go to
Import Geometry. Click Browse and select graphics_card_simple.stp to load the geometry.
The file graphics_card_simple.stp can be found at ICEPAK_ROOT/tutorials/Workbench.
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. Keep the selection of Meter as the desired length unit and press OK.
b. Click Generate to display the model.
c. 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. Select All objects for Selection Filter.
ii. 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.
d. Close DesignModeler and return to ANSYS Workbench.

3. Drag and drop an Icepak template into the Project Schematic on top of the Geometry cell (A2) to
transfer the geometry into ANSYS Icepak.
4. 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 ( ) to display the isometric view of the model.
b. 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.
Table 23.1 Object Properties

Object New name Solid Material Total Power
SERIAL_PORT SERIAL_PORT default 0.0 Watts
MEMORY1 MEMORY_1 Ceramic_material 5 Watts
MEMORY1.1 MEMORY_2 Ceramic_material 5 Watts
CAPACITOR CAPACITOR_1 default 0.0 Watts
CAPACITOR.1 CAPACITOR_2 default 0.0 Watts
KB KB default 0.0 Watts
HEAT_SINK HEAT_SINK default 0.0 Watts
CPU CPU Ceramic_material 20 Watts
ALHPA_MAIN_PCB PCB Custom- PCB solid_material 0.0 Watts
Conductivity type- Ortho-

tropic
X = 20, Y = 0.4, Z = 20
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.
c. Resize edit the properties of the default cabinet in the Cabinet panel.
Model → Cabinet
i. In the Cabinet panel, click the Geometry tab. Under Location, enter the following coordinates:
Table 23.2 Coordinates for the Cabinet

xS = -0.19 m xE = 0.03 m
yS = 0 m yE = 0.02848 m
zS = -0.11 m zE = 0 m
ii. Edit the cabinet properties to specify Min x and Max x sides as openings.
A. 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.
B. Select Edit to display the opening for the Max x object panel.
C. 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. The final model should correspond to the one shown below.
Figure 23.2 The Final Model Display
Note
For more information on how to refine a mesh locally, refer to Refining the Mesh Locally in
the Icepak User's Guide.
1. Click the assembly toolbar icon ( ) to create an assembly. Add the HEAT_SINK and CPU objects to
the assembly and rename it CPU_assembly.
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.
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.
Table 23.3 Slack Values

Min X = 0.005 m Max X = 0.005 m
Min Y = 0.0016 m Max Y = 0 m
Min Z = 0.001 m Max Z = 0.005 m
3. Specify the overall mesh controls as shown in the Mesh control panel below.
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.

1. Go to Problem setup → Basic parameters in the Model manager window.
a. In the General setup tab, make sure that both flow and the temperature fields are switched on.
b. Select Turbulent and Zero equation for the Flow regime and turn Off the Radiation.
c. Click Accept to close the panel.
2. 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

1. Go to File → Save project.
Note
You can click the save icon ( ) in the File commands toolbar.
The Save As panel appears.

2. Specify the name ice_wb for your project and click Save.
3. ANSYS Workbench will close ANSYS Icepak to save the model, you will need to launch ANSYS Icepak
again to continue.

1. Go to Solve → Run solution to display the Solve panel.
2. Keep the default settings in the Solve panel.
3. Click Start solution to start the solver.
ANSYS Icepak begins to calculate a solution for the model and a separate window opens where
calculation. Note that the actual values of the residuals may differ slightly on different machines,
so your plot may not look exactly the same as the figure below.
Step 7: Examine the Results with CFD-Post
4. Once the solution converges, click Done in the Solution residuals window to close it.
23.10. Step 7: Examine the Results with CFD-Post
Note
The postprocessing of results can be done within ANSYS Icepak; however, you can also ex-
amine results in ANSYS CFD-Post. This section will describe how to transfer information to
ANSYS CFD-Post and use its postprocessing options, so you may close ANSYS Icepak.
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. Double click the C2 Results cell to launch ANSYS CFD-Post. The model should appear in the display
window.
3. To generate contours, please do the following:
a. Go to Insert → Contour or click on the Contour button to create a contour. Retain the name
“Contour 1” and click OK.
b. In the Geometry tab under Details of Contour 1:
i. Keep the default selection of All Domains in the Domains drop-down list.
ii. 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.
Note
You can select multiple objects by holding down either Shift or Ctrl and se-
lecting the objects.
iii. Select Temperature in the Variable drop-down list.

iv. Select Apply to display the contours.
4. To generate a 3D streamline, please do the following:
a. Go to Insert → Streamline or click on the Streamline button to create the streamline. Retain
the name “Streamline 1” and click OK.
b. In the Geometry tab under Details of Streamline 1:
i. Keep the default selection of 3D Streamline in the Type drop-down list.
ii. Keep the default selection of All Domains in the Domains drop-down list.
iii. Select cabinet_default_side_maxx minx from the Start From drop-down list.
iv. Keep the default selection of Velocity in the Variable drop-down list.
v. Keep all other defaults and click Apply to display the streamline.
c. 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.
Step 9: Summary
23.11. Step 8: Thermo-Mechanical Structural Analysis

In addition to solving this problem in ANSYS Icepak, you can also perform a static structural analysis.
1. Select Static Structural from the Toolbox and drag and drop this cell on top of the Icepak Solution
cell (B3).
2. Click on the Geometry cell (A2) and drag and drop it on top of the Static Structural Geometry cell
(D3). The geometry is now shared.
3. Right click on the Setup cell (D5) and click Update.

4. Double click on the Model cell ( D4) to launch ANSYS Mechanical.
5. Click on the Imported Body Temperature object. This object is found under the Imported Load
(Solution) node.
6. 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. Select All from the Icepak Body drop-down list.
8. Click Solve.

In this tutorial, you imported CAD objects and set up a problem. You then created a non-conformal
mesh using the hex-dominant mesher. This forced convection problem was solved for flow and heat
transfer and the results were examined on contours and 3D streamlines in the model.
Chapter 24: Postprocessing Using ANSYS CFD-Post
24.1. Introduction
This tutorial demonstrates the use of ANSYS CFD-Post for post-processing results from ANSYS Icepak
analyses.
• Create a workflow in ANSYS Workbench.

• Postprocess ANSYS Icepak results in ANSYS CFD-Post.
24.2. Prerequisites
• Familiarity with the ANSYS Workbench interface
• Familiarity with the ANSYS Icepak interface
Figure 24.1 Quick Reference - CFD Post Interface
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.

Figure 24.3 (p. 352) shows the ANSYS Icepak model of a graphics card that contains a printed circuit
board. The board components include memory cards, capacitors, CPU, and serial connectors for peri-
pheral devices. The CPU is cooled by a heat sink. A fan and grille have been used to enhance the con-
vective heat transfer within the system. Two configurations, varying the positioning of the fan and grille,
will be considered for CFD analysis.
Figure 24.3 Problem Schematic - Graphics Card Model (two configurations)

1. Create a workflow by linking ANSYS Icepak and ANSYS CFD-Post in ANSYS Workbench.
a. Start a new ANSYS Workbench session.
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).
Figure 24.4 Creating an ANSYS Icepak Component
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.
Figure 24.5 Renaming the ANSYS Icepak Component Module
d. As shown in Figure 24.6 (p. 354) and Figure 24.7 (p. 354), drag and drop a Results (ANSYS CFD-
Post) 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.
Figure 24.6 Linking the Results (ANSYS CFD-Post) Component to the ANSYS
Icepak Component
Figure 24.7 Final Project Schematic
e. Save the project using File/Save (name the project as ice-cfdpost) from the ANSYS Workbench
interface.
2. Import project into ANSYS Icepak
a. Right click the ANSYS Icepak Setup cell and import the packed ANSYS Icepak project file ice-
cfdpost.tzr located in the project directory.
b. The ANSYS Icepak interface will launch with the selected project loaded for modeling/analysis.
24.5. Step 2: Parametric Trials and Solver Settings

1. Go to Edit → Preferences → Postprocessing and confirm that Merge zones when possible for
CFD-post data option is selected.
2. Go to Solve → Run solution → Results and verify that Create Heat Flux Vector in CFD Post is
enabled and click Dismiss.
Step 4: Postprocessing Using ANSYS CFD-Post
3. Go to Solve → Run optimization.

a. In the Design variables tab, review the parametric setup.
b. In the Trials tab, note that two of the four trials will be considered for CFD analysis.
Figure 24.8 Solution Trials

1. Click Run in the Parameters and optimization panel.
2. ANSYS Icepak will run two trials and automatically write out the results for post-processing in ANSYS
CFD-Post at the end of each trial.
3. Save the project by going to File → Save project.
4. Close ANSYS Icepak by going to File → Close Icepak.
24.7. Step 4: Postprocessing Using ANSYS CFD-Post

1. Open the results in ANSYS CFD-Post.
a. On the project schematic, double click the Results cell to launch the ANSYS CFD-Post interface.
b. ANSYS CFD-Post automatically reads in the most recent solution set (trial 004).
2. Create a Surface Group for the board and all the components.
a. Go to Insert → Location → Surface Group.

b. 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)).
Figure 24.9 Details View for BoardANDComponents Surface Group
d. In the Geometry tab, click next to Locations to open the Location Selector panel.
i. 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.
Figure 24.10 Selection for the BoardANDComponents Surface Group
ii. Click OK to close the Location Selector panel and add the surfaces.
e. Click Apply in the Geometry tab to apply the settings.
3. Create another Surface Group for the cabinet.
a. Go to Insert → Location → Surface Group and name the group CabinetSurfaces.
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.
Figure 24.12 Selection for the CabinetSurfaces Surface Group
c. In the Render tab, apply the settings as shown in Figure 24.13 (p. 358) and click Apply.
Figure 24.13 Rendering Details for the CabinetSurfaces Surface Group
d. Uncheck the BoardANDComponents object from User Locations and Plots.
Figure 24.14 Updated Model
e. Note that these newly create Surface Groups are listed under User Locations and Plots in the
Outline tab.
4. Plot Contours of Temperature on the Surface Group BoardANDComponents.
a. Change the Units for this postprocessing session.
i. Go to Edit → Options → Units.
ii. Set the System to Custom.
iii. Set the unit for Temperature to C.
Figure 24.15 Setting Units in CFD Post
iv. Click Apply and then OK to set the units and close the panel.
b. Go to Insert → Contour and create a new contour object named TemperatureContours.
c. 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.
Figure 24.16 Geometry Settings for TemperatureContours
d. Go to the Render tab and deselect Show contour lines.

e. 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. Double click Default Legend View 1 listed under User Locations and Plots to access the corres-
ponding Details view.
b. Modify the settings in the Definitions and the Appearance tabs as shown in Figure 24.17 (p. 362)
and click Apply.
Figure 24.17 Settings for Default Legend View 1
Figure 24.18 Modified Legend View
6. Plot Vectors, displaying heat flux on the Surface Group BoardANDComponents.
a. Deselect TemperatureContours in the User Locations and Plots node.

b. Go to Insert → Vector and create a new Vector object named HeatFluxVectors and click
OK.
c. Modify the Geometry tab of the Details view as shown in Figure 24.19 (p. 363) and click Apply.
Figure 24.19 Geometry Settings for HeatFluxVectors
Figure 24.20 Display of HeatFluxVectors
7. Plot Thermal Chokepoint, displaying regions of high heat flux on the Surface Group BoardANDCom-
ponents.
a. Deselect HeatFluxVectors in the User Locations and Plots node.
b. Go to Insert → Contour and create a new Contour object named Chokepoint and click OK.
c. 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.
Figure 24.21 Selection for Thermal Chokepoint
d. Modify the Geometry tab of the Details view as shown in Figure 24.22 (p. 365) and click Apply.
Figure 24.22 Geometry Settings for Chokepoint
Figure 24.23 Display of Chokepoint
8. Plot Streamlines originating from the fan and colored by temperature.

a. Deselect Chokepoint and select TemperatureContours in the User Locations and Plots
node.
b. Go to Insert → Streamline and create a new Streamline object named StreamlinesFan and
click OK to access the Details view panel.
c. Modify the Geometry tab as shown in Figure 24.24 (p. 367) and click Apply.
Figure 24.24 Geometry Settings for StreamlinesFan
d. Modify the Color tab as shown in Figure 24.25 (p. 367) and click Apply.
Figure 24.25 Color Settings for StreamlinesFans
e. Modify the Symbol tab as shown in Figure 24.26 (p. 368) and click Apply.
Figure 24.26 Symbol Settings for StreamlinesFan
Figure 24.27 Display of StreamlinesFan
9. Create a Keyframe Animation of StreamlinesFan.

a. Go to Tools → Animation and select Keyframe Animation.
b. Click the button to insert a new frame called KeyframeNo1 as shown in Figure 24.28 (p. 369).
Figure 24.28 Keyframe Animation Panel
c. Right click the background next to the model in the 3D viewer and select the View from +Y option
under Predefined Camera.
Figure 24.29 View From +Y
d. Add another keyframe called KeyframeNo2 to the Animation panel.

e. 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 ).
f. Similarly, update the display and add new frames as follows:
i. View from -Z and add KeyframeNo3.
ii. View from +X and add KeyframeNo4.

iii. Isometric view (Y up) and add KeyframeNo5.
g. Click to view the animation.

h. Click the Options button on the Animation panel to access the Animation Options panel.
i. Set the Animation Speed to Slower from the drop-down menu by a factor of 20 and click OK.
Figure 24.30 Animation Options Panel
j. Replay the animation and note that the animation is less choppy compared to the original one.
k. Close the Keyframe Animation panel.
l. Deselect the TemperatureContours and StreamlinesFan objects under User Locations
and Plots.
10. Create a Plane object displaying temperature contours and velocity vectors.
a. Go to Insert → Location → Plane and create a plane named PlaneCut.
b. Modify the Details for PlaneCut as shown in Figure 24.31 (p. 371) and click Apply.
Figure 24.31 Details for PlaneCut
c. Deactivate the display of the plane by deselecting PlaneCut and activate the contour display
by selecting TemperatureContours under User Locations and Plots.
d. 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.
Figure 24.32 Details for TemperatureContours
Figure 24.33 Display of PlaneCut
e. Go to the Details view for the PlaneCut (do not activate the display of the PlaneCut) and
make the following modifications:
i. Switch Method to XY Plane and click Apply.
ii. 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. Go to Tools → Animation and select Quick Animation (default) and highlight the PlaneCut
object.
ii. Using the scroll bar, adjust the number of frames for the animation as shown in Figure
24.34 (p. 373) and click the button.
Figure 24.34 Quick Animation Settings
iii. The animation can be viewed on the screen or can be written out to an animation file by
checking the Save Movie option.
iv. Stop the animation by clicking the button.

v. Close the Animation panel.
g. Deactivate the display of the contours by deselecting the TemperatureContours object under
User Locations and Plots.
h. Go to Insert → Vector and create a vector object named VelVectors.
i. Modify the Details for VelVectors to set the Location to PlaneCut and click Apply.
j. As before, use the Details view for the PlaneCut to manually traverse the plane displaying the
vectors across the domain.
k. Deactivate the display of the vectors by deselecting Velvectors under User Locations and
Plots.
11. Create an Isosurface of 27°C and 3 m/s.
a. Go to Insert → Location → Isosurface and create an Isosurface name HotSpots.
b. Modify the Details for HotSpots to create an isosurface for 27°C (Variable: Temperature,
Value: 27°C).
c. Similarly, modify the Details to create an isosurface for 3 m/s (Variable: Velocity, Value: 3
m/s).
d. Deactivate the display of the isosurface by deselecting HotSpots under User Locations and
Plots.
12. Create a Volume for values above 25°C.
a. Go to Insert → Location → Volume and create a Volume named IsoVolume.
b. Modify the Details for IsoVolume as shown in Figure 24.35 (p. 374) and click Apply.
Figure 24.35 Details of IsoVolume
Figure 24.36 Display of IsoVolume
c. Deactivate the display of the volume by deselecting IsoVolume under User Locations and
Plots.
13. Create a Chart of Temperature variation across a Line.

a. Go to Insert → Location → Line and create a Line named ForChart.
b. Modify the Details for ForChart as shown in Figure 24.37 (p. 375). and click Apply.
Figure 24.37 Details for Line ForChart
c. Deactivate the display of the line by deselecting ForChart under User Locations and Plots.
d. Go to Insert → Chart to create a Chart named TemperatureVariation.
e. Modify the Details for TemperatureVariation as follows:
i. General tab: Set the Type to XY.
ii. General tab: Set the Title to Temperature Variation along Z axis.
iii. Data Series tab: Set Location to ForChart.
iv. X Axis tab: Set Variable to Z.
v. Y Axis tab: Set Variable to Temperature.
f. Leave all other settings as their defaults and click Apply.
Figure 24.38 Plot of TemperatureVariation Along ForChart
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.
i. Right click in the white space and click New to create a new expression named VelocityR-
atio.
ii. Click Ok to access the Details view for VelocityRatio.

iii. 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 VelocityR-
atio.
iv. Create the expression as shown in Figure 24.39 (p. 377) and click Apply.
Figure 24.39 Expression for VelocityRatio
Note
Velocity is found under Variables, volumeAve()@ is found under Functions

→ CFDPost, and default_fluid is found under Locations → Other.
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. Click Ok to access the details view for VelRatio.

iii. Select Expression for the Method and set VelRatio to correspond to the Expression
VelocityRatio.
iv. Click Apply to create VelRatio.
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.
24.8. Step 5: Comparison Study

1. Open a new ANSYS CFD-Post session
a. Go to File → Close CFD Post to close the existing ANSYS CFD-Post session.
b. In the ANSYS Workbench project schematic, right click the Solution cell of the parametric setup
component to transfer the solution data to a new Results component, as shown in Figure
24.40 (p. 379).
c. Rename the Results component to Comparison Study.
Step 5: Comparison Study
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.
Figure 24.41 The Load Results Panel
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. Rotate, Zoom, or Pan one of the displays and confirm that the other display follows suit.
c. Using the Shortcuts Toolbar, modify the display to a landscape view (switch from to )
4. As before, go to Insert → Location → Surface Group and create a Surface Group named Board-
AndComponents.
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.
Step 5: Comparison Study
Figure 24.42 Display of BoardANDComponents
5. Deselect BoardAndComponents from User Locations and Plots.

6. 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.
7. Update the display of the Default Legend View (each display will need to be updated individually)
as before.
Figure 24.43 Display of Legend View
8. Go to Insert → Streamline and create a Streamline object named StreamlinesFans and edit
the Details as below:
a. Geometry tab: Select fan1_minx from both solution sets for Start From and set # of Points to
50.
b. Color tab: Set Mode to Variable and select Temperature for Variable.
c. Symbol tab: Select Show Symbols and Show Streams. Set the Interval to 0.005 s.
d. Click Apply.
Step 6: Summary
Figure 24.44 Display of Streamlines Comparison
e. Perform a detailed comparison study using the various features (Isosurface, Plane, Animation
etc.) discussed earlier in this tutorial.

In this tutorial, you learned how to import an ANSYS Icepak project from a .tzr file in ANSYS Workbench.
You then learned how to use a solution that was solved in ANSYS Icepak and postprocess it in ANSYS
CFD-Post. You also learned how to compare parametric solutions side-by-side in ANSYS CFD-Post.
Chapter 25: High Density Datacenter Cooling
25.1. Introduction
This tutorial demonstrates how to model a datacenter using ANSYS Icepak.
• Use macros to create computer room air conditioning units (CRACs), server cabinets, power distribution
units (PDUs), and perforated floor tiles in the datacenter.
• Organize the model using groups.
• Include effects of gravity and turbulence in the simulation.
• Define object-specific meshing parameters.
• Create contours, particle traces, iso-surfaces to better understand the airflow patterns and temperature
stratification within the datacenter space.
25.2. Prerequisites
solved or read the tutorial "Finned Heat Sink" of this guide. Some steps will not be shown explicitly.

This tutorial considers a 1200 sq. ft. datacenter with a slab to slab height of 12 ft as shown in Figure
25.1 (p. 386). The datacenter consists of a 1.5 ft underfloor plenum and a 2 ft ceiling plenum. The CRACs
discharge cold air into the underfloor plenum. The cold air enters the main datacenter space mainly
through the perforated floor tiles and returns back to the air conditioning units as shown in Figure
25.2 (p. 386). The cooling load, as summarized in Table 25.1: Size and Capacity of Heat Sources in Datacen-
ter (p. 385) corresponds to the heat output from the server cabinets and the PDUs.
Table 25.1 Size and Capacity of Heat Sources in Datacenter

Heat Source Size Power
Server Cabinet 2 ft x 3 ft x 7 ft 3000 W
High Density 2 ft x 3 ft x 7 ft 7000 W
PDU 4 ft x 2 ft x 5 ft 3600 W
Figure 25.1 Geometry of the Datacenter Model
Figure 25.2 Expected Airflow Path

3. Specify a name for your project such as datacenter and click Create.
Step 2: Set Preferences
Note
25.5. Step 2: Set Preferences

1. Go to Edit → Preferences. The Preferences panel opens.
2. Go to Display in the Options node.
a. Select Float for the Color legend data format and enter 2 under Numerical display precision.
3. Go to Editing in the Options node.
a. Set the Default dimensions to Start/length.
4. Go to Object types in the Options node.
a. Turn off Decoration for all object types and update line Width to 2 for blocks, fans, openings,
plates, resistances and grilles.
Figure 25.3 The Preferences Panel - Object types
5. Go to Units in the Defaults node.

a. Click Set all to Imperial.
b. Click This project to apply the preferences to this project.

To build the model, you will first resize the cabinet to its proper size. Then you will create the features
of the datacenter, including CRACs (2), server cabinets (44), perforated floor tiles (44), raised floor (1),
dropped ceiling (1), return grilles (8), PDUs (2), cable trays (4), columns (2) and miscellaneous blockage
(1).
1. Resize the default cabinet.

a. Select the Cabinet in the Model tree and specify the following in the object geometry window:
b. Press Apply to resize the cabinet.
c. 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. Set the Name to raisedfloor.
ii. Change the Plane to xz.
iii. Enter the following dimensions:
iv. Press Apply to resize and rename the object.

3. Create the first CRAC unit.
a. Go to Macros → Datacenter components → CRAC to open the CRAC panel.
b. Enter the dimensions as shown below in Figure 25.4 (p. 389).

c. Make sure the Flow direction is -Y.
d. Select Mass flow rate and input a value of 15.9 lbm/s.
e. Specify a Supply temperature of 55 F.
Figure 25.4 The CRAC Panel
Note
Mass flow rate has units of lbm/s.
f. Press Accept to create the CRAC unit.
Figure 25.5 The CRAC Unit in the Graphics Window
4. Set the per-object meshing parameters for the fans crac_intake and crac_exhaust.
a. Open the Mesh control panel by clicking the Generate mesh button ( ).
b. In the Local tab, check Object params and press Edit.
i. In the Per-object meshing parameters panel, Ctrl+left click crac_exhaust and
crac_intake to select both objects.
ii. Check the Use per object parameters option.
iii. Check the X count and Z count options and specify a Requested value of 4 for both options.
Figure 25.6 Per-object Meshing Parameters for the Fans
c. Click Done to close the Per-object meshing parameters panel.

d. Click Close to close the Mesh control panel.
5. Create a new group for the CRAC unit.
a. Select all the CRAC objects by Shift+left clicking cracunit and then crac_exhaust in the
b. Right click one of the selected objects and go to Create and then Group.
c. In the Create group panel, enter CRACs in the Name for new group text field.
d. Press Done to create the new group.

6. Create the second CRAC unit.
a. Expand the Groups node in the Model manager window.
b. Right click CRACs and select Copy.
c. In the Copy group panel, check Group name and enter CRACs.
d. Check Translate and set the Z offset to 10 ft.
Figure 25.7 The Copy Group CRACs Panel
e. Press Apply and Done to copy the CRAC unit and close the panel.
Figure 25.8 Two CRAC Units in the Graphics Window
f. Now may be a good time to Save the project ( ).

7. Create a row of server racks.
a. Go to Macros → Datacenter components → Rack (Front to Rear).
b. Input the dimensions as show below in Figure 25.9 (p. 394).
c. Set the Flow direction to -X.
d. Specify a Heat load of 3000 W.
e. Specify a Volume flow of 450 cfm.
f. Set the Number of racks to 11.
g. Under Create additional racks along select +Z.
Figure 25.9 The Rack (Front to Rear) Panel
h. Press Accept to create the server racks.
Figure 25.10 Row of Server Racks in the Graphics Window
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. Select all the server rack objects by Shift + left clicking rack and then rack-opns.10 in the
c. In the Create group panel, enter RACKs in the Name for new group text field.

9. Create a second row of server racks
a. Right click RACKs in the Groups node and select Copy.
b. In the Copy group panel, check Group name and enter RACKs.
c. Check Rotate and Translate in the Operations group box.
d. Set the Axis to Y and the Angle to 180.
e. Set the X offset to 7 ft.
Figure 25.11 The Copy Group RACKs Panel
f. Press Apply and Done to copy the row of server racks and close the panel.
Figure 25.12 Two Rows of Server Racks in the Graphics Window
10. Create a row of high density server racks.

a. Go to Macros → Datacenter components → Rack (Front to Rear).
b. Enter hdrack in the Name text field.
c. Input the dimensions as show below in Figure 25.13 (p. 399).
d. Set the Flow direction to -X.
e. Specify a Heat load of 7000 W.
f. Specify a Volume flow of 1000 cfm.
g. Set the Number of racks to 11.
h. Under Create additional racks along select +Z.
Figure 25.13 The Rack (Front to Rear) Panel
i. Press Accept to create the high density server racks.

11. Create a new group for the high density server racks.
a. Select all the high density server rack objects by Shift+left clicking hdrack and then hdrack-
opns.10 in the Model manager window.
c. In the Create group panel, enter HDRACKs in the Name for new group text field.
12. Create a second row of high density server racks.
a. Right click HDRACKs in the Groups node and select Copy.
b. In the Copy group panel, check Group name and enter HDRACKs.
c. Check Rotate and Translate in the Operations group box.
d. Set the Axis to Y and the Angle to 180.
e. Set the X offset to 7 ft.
f. Press Apply and Done to copy the row of high density server racks and close the panel.
Figure 25.14 Two Rows of High Density Server Racks in the Graphics Window
13. Create a row of perforated tiles.

a. Go to Macros → Datacenter components → Tile.
b. Set the Number of tiles to 11.
c. Enter the dimensions as show below in Figure 25.15 (p. 401).
d. Choose +Z.
e. Enter 0.35 for Uniform under % Open area.
Figure 25.15 Tile Panel
f. Press Accept to create the tiles.
Figure 25.16 Row of Tiles in the Graphics Window
14. Set the per-object meshing parameters for all the resistance objects.
b. In the Local tab, press Edit next to the Object params option.
i. In the Per-object meshing parameters panel, Shift+left click tile and then tile.10 to
select all the resistance objects.
iv. Check the Y count option and specify a Requested value of 3.
Figure 25.17 Per-object Meshing Parameters for the Tiles

15. Create a new group for the perforated tiles.
a. Select all the tile objects by Shift+left clicking tile and then tile_open_bottom.10 in the
c. In the Create group panel, enter TILEs in the Name for new group text field.
16. Create three more rows of perforated tiles.
a. Right click TILEs in the Groups node and select Copy.
b. In the Copy group panel, check Group name and enter TILEs.
c. Check Translate and set the X offset to 2 ft.
d. Press Apply and Done to copy the row of perforated tiles and close the panel.
e. Right click TILEs in the Groups node again and select Copy.
f. In the Copy group panel, check Group name and enter TILEs.
g. Check Translate and set the X offset to 14 ft.
h. Press Apply and Done to copy both rows of perforated tiles and close the panel.
Figure 25.18 Four Rows of Tiles in the Graphics Window
17. Create the ceiling plenum.

a. Click the Create plates button ( ).
i. Set the Name to ceilingplenum.
ii. Change the Plane to xz.

18. Create a return grille.
a. Click the Create grille button ( ).
b. Double click the grille.1 object in the Model manager window to open the Grille panel.
c. In the Info tab, enter ceiling-return under Name and enter CEILING-RETURN under
Groups.
d. In the Geometry tab, set the Plane to X-Z and enter the following dimensions:
e. In the Properties tab, set the Free area ratio to 0.5.

f. Press Done to apply the settings and close the panel.
19. Create two rows of return grilles.
a. Right click CEILING-RETURN in the Groups node and select Copy.
b. Set the Number of copies to 2.
c. In the Copy group panel, check Group name and enter CEILING-RETURN.
d. Check Translate and set the Z offset to 9 ft.
e. Press Apply and Done to copy the return grille and close the panel.
f. Right click CEILING-RETURN in the Groups node again and select Copy.
g. In the Copy group panel, check Group name and enter CEILING-RETURN.
h. Check Translate and set the X offset to -14 ft.
i. Press Apply and Done to copy the row of return grilles and close the panel.
Figure 25.19 Two Rows of Return Grilles in the Graphics Window
20. Create two more return grilles.

a. Click the Create grille button ( ).
b. Double click the newly created object to open the Grille panel.
c. In the Info tab, enter ceiling-return-crac1 under Name and select CEILING-RETURN
from the Groups drop-down list.
d. In the Geometry tab, set the Plane to X-Z and enter the following dimensions:
e. In the Properties tab, set the Free area ratio to 0.5.

f. Press Done to apply the settings and close the panel.
g. Right click the vent ceiling-return-crac1 from the Model tree and select Copy.
h. In the Copy group panel, check Group name and enter CEILING-RETURN.
i. Check Translate and set the Z offset to 10 ft.
j. Press Apply and Done to copy the return grille and close the panel.
k. Right click ceiling-return-crac1.1 and Rename the object to ceiling-return-crac2.
Figure 25.20 Two CRAC Return Grilles in the Graphics Window
21. Set the per-object meshing parameters for the return grilles.
b. In the Local tab, press Edit next to the Object params option.
i. In the Per-object meshing parameters panel, Shift+left click ceiling-return and then
ceiling-return.3 to select all the return grilles.
Figure 25.21 Per-object Meshing Parameters for the Return Grilles

22. Create a PDU.
a. Go to Macros → Datacenter components → PDU to open the PDU panel.
b. Enter the dimensions as shown below in Figure 25.22 (p. 409).
c. Set the PDU flow direction to +Y.
d. Set the Heat output to 3600 W.
e. Set the Percent open area on top and the Percent open area on bottom to 0.25.
Figure 25.22 The PDU Panel
f. Press Accept to create the PDU.

23. Set the per-object meshing parameters for the grilles pdu_vent_in and pdu_vent_out.
b. In the Local tab, check Object params and press Edit.
i. In the Per-object meshing parameters panel, Ctrl+left click pdu_vent_in and
pdu_vent_out to select both objects.
24. Create a new group for the PDU.
a. Select all the PDU objects by Shift+left clicking pdu_unit and then pdu_part4 in the Model
manager window.
c. In the Create group panel, enter PDUs in the Name for new group text field.
25. Create the second PDU.
a. Right click PDUs in the Groups node and select Copy.

b. In the Copy group panel, check Group name and enter PDUs.
c. Check Translate and set the X offset to 14 ft and the Z offset to 28 ft.
d. Press Apply and Done to copy the PDU and close the panel.
Figure 25.23 Two PDUs in the Graphics Window
e. Now may be another good time to Save the project ( ).

26. Create blockages.
a. Click the Create blocks button ( ).

i. Set the Name to piping and the Group to BLOCKAGE.
ii. Set the Type to Hollow.
c. Click the Create blocks button ( ).

d. In the object geometry window:
i. Set the Name to blockage and the Group to BLOCKAGE.

27. Create columns.

i. Set the Name to column1 and the Group to COLUMNS.
c. Click the Create blocks button ( ).

d. In the object geometry window:
i. Set the Name to column2 and the Group to COLUMNS.

28. Create cabletrays.

i. Set the Name to cabletray1 and the Group to CABLETRAYS.

c. Create three more cabletrays.
i. Right click CABLETRAYS in the Groups node and select Copy.
ii. In the Copy group panel, check Group name and enter CABLETRAYS.
iii. Check Translate and set the X offset to 6 ft.
iv. Press Apply and Done to copy the cabletray and close the panel.
v. Right click CABLETRAYS in the Groups node again and select Copy.
vi. 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.
Figure 25.24 The Completed Model
Step 5: Create Monitor Points

1. Click the Generate mesh button ( ).
2. In the Mesh control panel, enter 2 ft, 0.5 ft, and 1 ft for the Max element size for x, y, and z, respect-
ively. Change the Minimum gap values to 1 in, 0.36 in, and 1 in for x, y and z, respectively.
Figure 25.25 Mesh Control Panel
Note
The units for the Minimum gap values are in inches.
3. Click Generate.
4. Use the Display and Quality tabs to view the mesh and check the mesh quality.
5. Click Close to close the panel once you have finished viewing the mesh.
25.8. Step 5: Create Monitor Points

Create two temperature monitor points for the CRAC fans exhaust fans by dragging crac_exhaust
and crac_exhaust.1 from the Model node to the Points node. ANSYS Icepak will automatically
monitor values at the centers of these objects. The default setting is to monitor Temperature. You can
also monitor Pressure and/or Velocity by double clicking the monitor point in the Points folder and
choosing which variables to monitor at that location.
Figure 25.26 Creating Monitor Points

a. In the General setup tab:
i. Turn Off the Radiation.
ii. Select Turbulent and Zero equation for the Flow regime.
iii. Enable the Gravity vector.
b. In the Defaults tab:
i. Select Mica-Typical from the Insulators section of the Default solid drop-down list.
ii. Select Paint-non-metallic from the Paint section of the Default surface drop-down list.
c. In the Transient setup tab:
i. Set the initial Y velocity to be 0.5 ft/s (a non-zero initial velocity is recommended for
problems involving natural convection).
d. In the Advanced tab:
i. Select the Ideal gas law (recommended for problems involving significant temperature dif-
ferences).
ii. Check Operating density and keep the default value.
e. Press Accept to apply the settings and close the panel.
a. Change the Number of iterations to 1000 and the Convergence criteria for Energy to 1e-6.
b. Click Accept to apply the settings and close the panel.
a. Set the Discretization scheme for Pressure as Body Force Weighted.
b. Set the Under-relaxation to 0.2 for Momentum and to 0.1 for Body forces.
c. Click Accept to apply the settings and close the panel.


1. Go to Solve → Run solution.
2. In the Results tab, check Write CFD Post data.
ANSYS Icepak begins to calculate a solution for the model, and a separate window opens where
calculation.
Upon completion of the calculation, your residual and monitor plots will look something like Figure
25.27 (p. 416) and Figure 25.28 (p. 417). You can zoom in the residual plot by using the left mouse.
Note
plots may not look exactly the same as Figure 25.27 (p. 416) and Figure 25.28 (p. 417).
Figure 25.27 Solution Residuals
Figure 25.28 Temperature Point Monitors
4. Click Done in the Solution residuals and Temperature Point monitors windows to close them.

The objective of this exercise is to consider the airflow patterns and identify problem areas such as hot
spots, stagnant zones, and recirculation zones through out the datacenter. You will accomplish this by
examining the solution using ANSYS Icepak's graphical postprocessing tools.
1. Display contours of temperature on the CRACs, Racks, and PDUs.
a. Click the Object face button ( ).

b. Enter surface-temp-contours in the Name field.
c. In the Object drop-down list, expand the Groups node and Ctrl+left click CRACs, HDRACKs,
PDUs, and RACKs, and click Accept.
d. Check Show contours and click Create.

e. Click Done to close the panel.
Figure 25.29 Object Face Temperature Contours
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.
b. Click the Plane cut button ( ).

c. Enter plane-temp-contours in the Name field.
d. Check Show contours and click Create to view a plane cut of the temperature contours.
Figure 25.30 Plane Cut Temperature Contours
e. 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.
f. Click Interrupt on the progress bar to return to the Plane cut panel.
g. Repeat the above procedure for plane cuts in the Y-Z and X-Z planes by changing the Set pos-
ition to X plane through center and Y plane through center respectively.
h. Click Done to close the panel.
3. Display animated contours of temperature on an isosurface.
a. Right click plane-temp-contours in the Model manager window and make the plane cut
inactive by unchecking Active in the context menu.
b. Click the Isosurface button ( ).

c. Enter iso-temp in the Name field.
d. Enter 90 in the Value field.
e. Check Show contours and click Create to view the isosurface of 90°F.
Figure 25.31 Isosurface of 90°F
f. To view an a loop of isosurfaces from 90°F to 80°F:

i. In the Animation group box, enter 90 for Start, 80 for End, and 10 for Steps.
ii. Check the Loop mode option and click Animate.
iii. Click Interrupt on the progress bar to return to the Isosurface panel.
g. Click Done to close the panel.
4. Display airflow patterns in the datacenter.
a. Right click iso-temp in the Model manager window and make the isosurface inactive by un-
checking Active in the context menu.
b. Click the Object face button ( ).

c. Enter airflow in the Name field.
d. In the Object drop-down list, expand the Groups node and Ctrl+left click CEILING-RETURN,
HDRACKs, PDUs, RACKs, and TILEs, and click Accept.
e. Check Show particle traces and click Parameters.

f. Set the Display options to Mesh points.
g. Set the End time under Particle options to 5.
h. Check Loop mode under Animation and set the Steps to 50.
i. Click Apply to display the airflow patterns.
Note
ANSYS Icepak will take a few moments to generate the airflow patterns.
Figure 25.32 Particle Traces
j. Click Animate to visualize the airflow patterns in a transient manner.

k. View the animated airflow patterns from various angles from the Orient menu.
l. Press Interrupt to stop the animation.
m. Click Done in the Object face particles and Object face panels to close them.
n. Right click airflow in the Model manager window and make the particle traces inactive by
unchecking Active in the context menu.
5. Report the volumetric flow rate distribution at the perforated floor tiles.
a. Go to Report → Summary report to open the Define summary report panel.
b. Click New to get a new field to define the Summary report.
c. In the Objects drop-down list, expand the Groups node and select TILEs, and click Accept.
d. Select Volume flow from the Value drop-down list and deselect Comb.
e. Click Write to display the summary report.
f. Click Done to close the Report summary data panel.

g. Click Close to close the Define summary report panel.
6. Save ( ) the project and Close ANSYS Icepak.
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.

In this tutorial, you learned how to model a datacenter using macros, and how to organize a model
using groups. You also learned how to use animated postprocessing objects to examine the results.
Chapter 26: Design Modeler - Electronics
26.1. Introduction
This tutorial demonstrates how to use ANSYS DesignModeler to convert a model for analysis in ANSYS
Icepak.
• Use the Slice, Opening, Fan, and Simplify options in ANSYS DesignModeler.
• Organize the model using Parts.
26.2. Prerequisites
• Familiarity with the ANSYS Workbench interface
• Familiarity with the ANSYS Icepak interface

You will convert an imported STEP file for use in ANSYS Icepak. Figure 26.1 (p. 425) shows the geometry
in ANSYS DesignModeler before the conversion and in ANSYS Icepak after conversion.
Figure 26.1 Comparison of the Geometry in ANSYS DesignModeler and ANSYS Icepak

1. Open ANSYS DesignModeler through ANSYS Workbench.
a. Start a new ANSYS Workbench session.
b. 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).
c. 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.
Figure 26.2 Creating a Geometry Component Module
d. Save the project (name the project as DME).

e. Double click cell A2 to open ANSYS DesignModeler.

1. Once ANSYS DesignModeler opens, select Millimeter as the desired unit, and press OK.
Step 3: Add Shortcuts to the Toolbar
2. Go to File → Import External Geometry File and select DME.stp and press Open.
3. Click to create the model.
Figure 26.3 Imported Model
26.6. Step 3: Add Shortcuts to the Toolbar

1. Go to Tools → Options
2. In the Options panel, go to DesignModeler → Toolbar.
3. Set Slice, Freeze, and Electronics to Yes.
Figure 26.4 Options Panel
4. Press OK to add the options to the toolbar.
Note
• The Electronics drop down menu in the toolbar contains several options:
• You can also access the option from the Create menu.
• You can also access the and Electronics options from the Tools menu.
26.7. Step 4: Edit the Model for ANSYS Icepak

1. Click to make the model transparent and to allow for the Slice operation.
2. Check which bodies are already recognized as ANSYS Icepak objects.
a. Go to Electronics → Show Ice Bodies. Only bodies with simple geometries recognized as ANSYS
Icepak objects will be visible.
Step 4: Edit the Model for ANSYS Icepak
Figure 26.5 Bodies Recognized as ANSYS Icepak Objects
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.
Figure 26.6 Bodies not Recognized as ANSYS Icepak Objects
Note
These are the bodies we will have to modify in order to export these bodies into
ANSYS Icepak.
c. Go to Electronics → Revert View to return to the previous display.

3. Create a Slice for one set of fins.
a. In the Tree Outline, right click Housing and select Hide All Other Bodies.
b. Select from the Shortcuts toolbar.
c. In the Details view, set the Slice name to FinsSlice1.
d. Select Slice by Surface for Slice Type.
e. 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.
Figure 26.7 FinsSlice1 Face Selection
Note
If you cannot select the face, try pressing the Model Faces selection filter ( ).
f. Make sure Slice Targets is set to Selected Bodies.

g. Click the field to the right of Bodies and select the Housing body.
h. Click Apply and then .
4. Likewise, create a Slice for the other set of fins.
a. Use the procedure described above on the other set of fins and name the second Slice FinsS-
lice2.
Note
Make sure that the Bodies selection is the larger section of the housing containing
the fins.
Figure 26.8 FinsSlice2 Bodies Selection
5. Create Parts for the sliced fins.
Note
The Parts will become Assemblies in ANSYS Icepak.
a. Press +Y on the Triad (the axes) to get a clear view of the fins.
b. Select Box Select from the Shortcuts toolbar.
c. Select the Bodies selection filter ( ).

d. 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).
Figure 26.9 Selecting a Row of Fins
e. Right click anywhere in the Model View and select Form New Part.
f. In the Details view, set the Part name to Fins1 and press enter on the keyboard.
g. Repeat steps a to f for the other set of fins, except name the part Fins2.
6. Create a Housing slice.
a. Select from the Shortcuts toolbar.
b. In the Details view, set the Slice name to HousingSlice1.
c. Select Single Select from the Shortcuts toolbar.
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.
Figure 26.10 HousingSlice1 Selection
e. Make sure Slice Targets is set to Selected Bodies.

f. Click the field to the right of Bodies and select the Housing object in between the fins.
Figure 26.11 HousingSlice1 Bodies Selection
g. Click Apply and then .

7. Create another Housing slice.
a. Select from the Shortcuts toolbar.
b. In the Details view, set the Slice name to HousingSlice2.
c. Select the inner face of the top of the Housing as shown in Figure 26.12 (p. 436) and press Apply.
Figure 26.12 HousingSlice2 Face Selection
d. Click the field to the right of Bodies and select the top part of the Housing object in between
the fins.
e. Click Apply and then .
f. You should have ten Housing objects outside of the Fins parts in the Tree Outline.
8. Create Openings for the fan.
a. Show all bodies again by right clicking one of the objects in the Tree Outline and clicking Show
All Bodies
b. Go to the +Y view.
c. Go to Electronics → Opening.
d. In the Details view, set the Opening name to FanOpenings.
e. Click the field to the right of Faces and select the face as shown in Figure 26.13 (p. 437) and press
Apply and .
Figure 26.13 FanOpenings Face Selection
9. Create Openings for the back panel.

a. Go to the -Y view.
b. Go to Electronics → Opening.
c. In the Details view, set the Opening name to BackOpenings.
d. Click the field to the right of Faces and select the face as shown in Figure 26.14 (p. 437) and press
Apply and .
Figure 26.14 BackOpenings Face Selection
10. Create a Fan.

a. Right click the Fan body in the Tree Outline and select Hide All Other Bodies.
Note
If you cannot view the object correctly, press Zoom to Fit ( ).
b. Go to Electronics → Fan.
c. In the Details view, set the Fan name to FanGeom.
d. Click the field to the right of Body To Extract Fan Data, select the entire fan body and press
Apply.
e. Click the field to the right of Hub/Casing Faces and select the faces as shown in Figure 26.15 (p. 438).
Figure 26.15 Hub/Casing Faces Selection
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.
g. Add the fan to the Front-Panel part.

i. In the Tree Outline, select the Front-Panel part and then Ctrl and left click the Fan object.
ii. Right click the Fan object and select Form New Part.
iii. In the Details view, rename the Front-Panel Part to Front-Panel-Fan.
11. Perform a Simplify operation on the Housing.
a. Show all bodies again by right clicking one of the objects in the Tree Outline and clicking Show
All Bodies
b. Go to Electronics → Simplify.
c. In the Details view, set the Simplify name to HousingFrontBack.
d. In the field to the right of Simplification Type, select Level 1.
e. 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).
Figure 26.16 HousingFrontBack Bodies Selection
f. Click Apply and .

12. Perform a Simplify operation on the PWB and the T0220 objects.
a. 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.
b. Right click one of the selected objects and select Hide Body to view just the internal components.
c. Go to Electronics → Simplify.
d. In the Details view, set the Simplify name to PWB_T0220.
e. In the field to the right of Simplification Type, select Level 1.
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. Go to the +Z view.
ii. Make sure the Select Mode is Single Select.
iii. Hold down Ctrl and select the objects as shown in Figure 26.17 (p. 440).
Figure 26.17 PWB_T0220 Bodies Selection
iv. Using this method, only the 13 correct bodies will be selected.
g. Click Apply and .
13. Add all the package objects to the Parts.
a. Change the Selection Mode to Box Select and make sure the selection filter is set to Bodies.
b. Select a package object as shown in Figure 26.18 (p. 441). There should be 6 bodies selected.
Figure 26.18 Package Object Selection
c. Right click the model and select Form New Part. All the bodies will be added to the part.
d. Name the part T0220_Case1.
e. Repeat steps a to e for the rest of the packages, except naming the parts T0220_Case2,
T0220_Case3, etc.
14. Perform a Simplify on the Coil.
a. Go to Electronics → Simplify.
b. In the Details view, set the Simplify name to CoilAssembly.
c. In the field to the right of Simplification Type, select Level 1.
d. 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.
Figure 26.19 Coil Bodies Selection
e. Click Apply and .

15. Add the rest of the Coil bodies to the part.
a. Make sure the selection filter is set to Bodies.
b. Make the same selection as in the simplify operation. Notice that there are now 8 bodies instead
of 4.
c. Right click the model and select Form New Part.
d. In the Details view, set the Part name to CoilAssembly2.
16. Perform a Simplify on the Capacitors.
a. Go to Electronics → Simplify.
b. In the Details view, set the Simplify name to Capacitors.
c. In the field to the right of Simplification Type, select Level 3.
d. 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.
Figure 26.20 Capacitors Bodies Selection
e. Click Apply.
f. Set the Face Quality to Medium
g. Click .
17. Form a part for the Capacitors.
b. Make the same selection as the simplify operation. There should still be 3 selected bodies.
c. Right click the model and select Form New Part.
d. In the Details view, set the Part name to Capacitors.
18. Form parts for the Heat Sink and Components.
b. Follow the same steps as before to create a part called BGAHS for the Heat Sink and Components
for the Components:
Figure 26.21 BGAHS and Components Parts Selections
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).
Figure 26.22 Final Model in ANSYS DesignModeler
Step 5: Opening the Model in ANSYS Icepak
Figure 26.23 Final Tree Outline
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. Go to Electronics → Show CAD Bodies.
b. Confirm that the view contains no bodies. This means all the bodies have been recognized by
ANSYS Icepak.
21. The model is now ready to use in ANSYS Icepak.
26.8. Step 5: Opening the Model in ANSYS Icepak

1. Go to File → Save Project and then File → Close DesignModeler.
2. In ANSYS Workbench, drag an ANSYS Icepak component to cell A2 to create an ANSYS Icepak component
module.
Figure 26.24 Creating an ANSYS Icepak Component Module
3. Double click the Setup cell (B2) to open the model in ANSYS Icepak.
4. In the model manager window, right click the Model node and select Expand all to view the geometry
inside the assemblies.
5. Notice that the bodies have been successfully transferred into ANSYS Icepak.
Step 6: Summary
Figure 26.25 Final Model

In this tutorial, you learned how to get a CAD model ready for ANSYS Icepak using ANSYS DesignModeler.
You used the slice, simplify, openings, and fan operations to convert the model.
individual side specification, 79
Index
J
B joule heating, 283
BGA-package, 157, 321
L
C loss coefficient, 143
CAD loss coefficient vs Re, 155
geometry, 245
import, 247 M
CFD Post, 351 mesh exercise, 133
CFD Post in Workbench, 351 microelectronics, 295
cold-plate, 97, 101 modeling
model layers separately, 281
D radiation, 196
Datacenter cooling monitor point, 308
high density, 385 mouse conventions, 2
Design Modeler multi-level meshing, 311, 314
electronics, 425
Dimensions tab, 322 N
non-conformal
E assembly, 101
Edit object panel, 7 mesh, 121, 127, 129
Electronics nested, 113
Design Modeler, 425
O
F object parameters, 221
finned heat sink, 3, 17 obtaining support, 2
Functions optimization run, 181
compound, 178 orthotropic material properties, 110
objective, 178
primary, 178 P
param value, 175
H parameterization, 71
heat pipe, 107, 113 parametric runs, 162
heat sink, 49 parametric trials, 147
finned, 3, 17 multiple trials, 84
inline or staggered, 157
heat transfer coefficient, 325 R
help radiation model
obtaining support, 2 discrete ordinates, 185, 197
hex-dominant, 257 ray tracing, 197
rf amplifier, 37, 53
I
Icepak in Workbench, 339 S
import search fan library, 50
CAD file, 247 summary report, 126
IDF, 235, 268 support
tcb file, 322 obtaining help, 2
trace layer, 271, 333
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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ANSYS Icepak Tutorials

ANSYS, Inc. Release 14.0

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Published in the U.S.A.

8.7. Step-by-Step Approach ................................................................................................................. 134

12.1. Introduction ............................................................................................................................... 185

15.4. Step 1: Create a New Project ........................................................................................................ 235

19.2. Prerequisites ............................................................................................................................... 295

23.1. Introduction ............................................................................................................................... 339

1.2. How To Use This Manual

1.2.1. For the Beginner

1.2.2. For the Experienced User

1.3. Typographical Conventions Used In This Manual

Model → Generate mesh

Problem setup → Basic parameters

1.4. Mouse Conventions Used In This Manual

1.5. When To Call Your ANSYS Icepak Support Engineer

In this tutorial you will learn how to:

• Create a new project.

2.3. Problem Description

Figure 2.1 Problem Specification

2.4. Step 1: Create a New Project

The New project panel appears.

3. Specify a name for your project and click Create.

2.5. Step 2: Build the Model

1. Resize the default cabinet in the Cabinet panel.

a. In the Cabinet panel, click the Geometry tab.

c. Click Done to resize the cabinet and close the panel.

2. Create the backing plate.

a. Click the Create blocks button ( ) to create a new block.

e. Click Done to modify the block and close the panel.

a. Click the Create openings button ( ) to create a new opening.

e. Click Done to modify the opening and close the panel.

a. Click the Create fans button ( ) to create a new fan.

f. Click the Properties tab.

i. Click Done to modify the fan and close the panel.

a. Click the Create sources button ( ) to create a source.

b. Click the Edit object button ( ) to open the Sources panel.

g. Click the Properties tab.

i. Click Done to modify the source and close the panel.

b. Click the Copy object button ( ).

f. Click the Properties tab.

j. Click Done to modify the plate and close the panel.

b. Click the Copy object button ( ).

Figure 2.2 Completed Model for the Finned Heat Sink

Model → Check model

View → Summary (HTML)

2.6. Step 3: Generate a Mesh

Model → Generate mesh

1. Generate a coarse (minimum-count) mesh.

e. Click the Generate button to generate the coarse mesh.

b. Turn on the Cut plane option.

The number of elements may vary slightly on different machines.

Figure 2.3 Coarse Mesh on the y-z Plane

Figure 2.4 Fine and Coarse Mesh on the y-z Plane

6. Turn off the mesh display.

Figure 2.5 Display mesh option

2.7. Step 4: Physical and Numerical Settings

1. Check the values of the Reynolds and Peclet numbers.

Solution settings → Basic settings

c. Click Accept to save the solver settings.

Problem setup → Basic parameters

b. Click Accept to save the new settings.