Work

An Advanced Multiphysics Numerical Framework for Cross-Flow Finned Heat Exchangers: Coupled Fluid–Solid Interaction and Thermal Optimisation

Year: 2026

Type: article

Abstract: Purpose: Therefore, the aim of this study is to develop and validate an advanced Multiphysics numerical framework capable of simultaneously analysing conjugate heat transfer (CHT) and one-way fluid–solid interaction (FSI) in finned cross-flow heat exchangers under realistic operating conditions. Design/Methodology/Approach: In this paper, coupled heat transfer and structural interaction for finned heat exchangers were studied using a detailed 3D numerical model. The finite-volume method and the SST k–ω turbulence model was employed. Considering realistic boundary conditions, the temperature-dependent material properties and interfacial resistance were modelled. Research Limitation: The present framework adopts a steady-state one-way FSI formulation and evaluates only selected geometric variables, namely fin spacing and fin height. Findings: Validation against both analytical correlations and the manufacturer's data shows a solid fit, with a deviation of 11%. The assessment verified that the largest share of the total thermal resistance is due to air-side convection, while the contact-resistance component always remains around 10%. Modifications to the fin geometry showed that a height of 10 mm and a spacing of 3 mm are the best trade-off between flow resistance and heat transfer, and that overall effectiveness increases by about 12%. Practical Implication: The established framework provides a solid basis for further optimisation analyses and supports the design of cost-effective, low-energy heat exchanger construction. Social Implication: Enhanced exchanger performance can therefore support lower greenhouse gas emissions, reduced operational energy costs, and more sustainable thermal management infrastructure in the residential and industrial sectors. Originality / Value: Most numerical studies remain stuck in a heuristic paradigm and overlook real conditions such as no contact resistance at the fin-tube interface, uneven airflow, and the flow-induced structural mechanics of the system.

Source: African Journal Of Applied Research

DOI: 10.26437/jtdyfv73

Authors: W. H. Al Doori, M. A. Kumbhalkar, M. M. Sardeshmukh, S. W. Shaikh, T. S. Sargar, S. V. Prayagi

Institutions: University of Tikrit, JSPM University, Yeshwantrao Chavan College of Engineering

Language: English

Topic: Heat Transfer and Optimization

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Affordable and clean energy

Open Access status: diamond

Funder: Tikrit University