Mean Velocity per channel:

um =

n Ac

A c =wch hch
Incompressible (constant density)

D =

Reynolds Number:

Dh u m

Flow will be laminar if reynolds number is less than approx.. 2300

Internal flow, based on mean velocity and hydraulic diameter, characteristic
dimensions of the duct cross section

D h=

Hydraulic diameter:

4 A c 2 w ch hch
=
per wch +h ch

per: wetted perimeter

wch = channel width
hch = channel height
Hydrodynamic entry length of laminar internal flow, distance required for the
momentum boundary layers to join

x fd ,h ,lam
0.06 D
Dh

(Nellis and Klein, 2008, pg 638)

Mean velocity and cross-sectional area are constant.

k: conductivity
thermal entry length, distance required for the thermal boundary layers to join.

x fd ,t , lam
0.06 D Pr
Dh
h

(Nellis and Klein, 2008, pg 647)

Ratio of thermal to hydrodynamic entry lengths

x fd , t ,lam
Pr
x fd ,h ,lam
Rate of momentum to thermal boundary layer development in laminar flow is
related to Prandtl number. PAO is viscous but not conductive, has a high Prandtl
number. Momentum boundary layer will grow more quickly than the thermal
boundary layer and the flow will become much sooner hydrodynamically fully
developed than it will become thermally developed. (Nellis and Klein, 2008, pg. 647)

Thermal and momentum boundary layer growth for high Prandtl number (Nellis and
Klein, 2008, pg. 648)
The roughness at the duct surface will affect the Nusselt number and friction factor
for a turbulent flow but not a laminar flow (Nellis and Klein, 2008, pg. 650)
For internal flow, pressure gradient correlated using the Moody (or Darcy) friction
factor.
Average or apparent friction factor.

f =( p x=0 p x= L ) 2 D h
l ch u2m
f l ch u2m
P=
2Dh
(Nellis and Klein, 2008, pg. 642)
lc =length of channel

Local and average friction factor as a function of position in the entrance region of
an internal flow.
The average friction factor will approach the local friction factor in the fully
developed region. However, because the average friction factor has some memory
of the developing region it will always be somewhat larger than the local value.
Necessary to calculate average in order to solve an engineering problem, need to
know the total pressure drop across a duct that must be overcome by a pump or
fan.
Friction factor, laminar, fully developed region. (Nellis and Klein, 2008, pg. 652)

f fd ,h =

96
(11.3553 AR+1.9467 AR 2 1.7012 AR 3 +0.9563 AR 40.2537 AR 5)
D
h

Average friction factor for laminar flow, rectangular ducts, approximately computed
using dimensionless position L+ and this equation.
L+ dimensionless position.

+=

l ch
Dh D
L

(Nellis and Klein, 2008, pg. 651)

+
L

0.00021
1+

3.44
(f

)
fd ,h
D
L+

+
4L +

4
1.25

+
L +
3.44

f 4
D
h

(Nellis and Klein, 2008, pg. 653)

Based off of Curr et al. (1972).

The product of the apparent friction factor in a rectangular duct and the Reynolds
number as a function of L+ for two values of the aspect ratio. The results predicted

by Eqs. (5-60) and (5-61) are shown, as well as the more exact solution provided by
Curr et al. (1972).
Local Nusselt number for a laminar, hydrodynamically and dully developed flow in a
rectangular duct exposed to unform heat flux.

Nu D , H , fd =8.235 (12.042 AR+3.085 AR 22.477 AR 3+1.058 AR4 0.186 AR 5 )

h

AR: Aspect ratio of duct (the ratio of the minimum to the maximum dimensions)
NuDh, H, fd = 7.929
The average Nusselt number will approach the local Nusselt number in the
thermally fully developed region. However, because the average Nusselt number
has some memory of the developing region, it will always be somewhat larger than
the local value.

Local and average heat transfer coefficient and Nusselt number as a function of
position. (Nellis and Klein, 2008. 646)
Can also use EES procedure DuctFlow_N, which interpolates a table of data provided
by Kakac et al. (1987) and corrects for the Prandtl number effects by applying the
correction associated with a square duct, also from Kakac et al. (1987).
call DuctFlow_N(Re,Pr,LoverD_h,ALPHA_c,relRough: {Nusselt_T}, Nusselt_H, f_app)

Inputs:
Re - Reynolds number based on properties evaluated at the bulk average
temperature
Pr - Prandtl number of the fluid evaluated at the bulk average temperature
LoverD_h - ratio of tube length to hydraulic diameter.

Aspect - ratio of the minimum to maximum dimension of duct. This value should be
<=1
RelRough - the ratio of the dispersions on the wall of the tube to the tube diameter
(must be between 0 and 0.05)
Outputs:
Nusselt_T - Nusselt number assuming a constant wall temperature
Nusselt_H - Nusselt number assuming a constant wall heat flux
f - apparent friction factor [-]
Use calculated local, conservative. Cant verify sources from Kakac.
Local heat transfer coefficient, correlated using a local Nusselt number that is based
on the hydraulic diameter.

Nu D =
h

h=

h Dh
k

Nu D k
Dh
h

K is thermal conductivity of the fluid.

h = 11411 W/m2-K

Calculating mean temperature from energy balance

Mean Temperature: used as referemce temperature for the flow. Represents the
thermal energy carried by the flow at a particular axial position.
Represents local rate at which the flow carries thermal energy (or enthalpy). Used to
define local heat transfer coefficient for an internal flow.

T m=

T u d AC

m
A
c

General steady state energy balance on a differential control volume

Steady-state energy balance on a differential control volume. (Nellis and Klein,

2008, pg. 672)

c u T d Ac k
Ac

Ac

T
d
d A c + gv ' '' A c dx+ g '' ' Ac dx + q s'' per dx= c u T d A c + c
x
dx
A
A
c

u T d Ac
Ac

dxk

Substituting definition of mean temperature and simplifying,

g v' ' ' A c + g ' ' ' Ac + q s' ' per=m c

Ac

d Tm d
+
dx dx

k x d A c
Ac

Will be a useful equation if flow geometry needs further analysis. (Nellis and Klein, 2008,
pg. 672)

q s'' =

q conv
w hx l hx

Whx: heat exchanger width

Lhx: heat exchanger length

q s' ' :heat flux from the duct wall to the fluid
gv ' '' : volumetric generation due to viscous dissipation
g' '' : externally iumposed volumetric generation in fluid (e.g. chemical reaction,
electrokinetic effects)

Ac

T
d
x

Assumptions: no externally imposed volumetric generation, no volumetric generation

related to viscous dissipation, no axial conduction, constant mass flow rate, fluid is
incompressible
Combine mean temperature equation
Simplified balance between energy input by convection at the wall with the change in
mean temperature of the fluid.

c
q s'' per =m

dTm
dx

Can be integrated directly to obtain Tm as a function of x. (Nellis and Klein, 2008, pg.
673)

per q s' ' '

T m=T +
x
m
cp
Because we evaluate our temperature at the exit, this mean temperature is simply the
fluid exit temperature
T = 44.63 C
Represents thermal energy carried by flow at a particular axial position: T is local
temperature of low.
Valid for incompressible fluids with constant specific heat capacity. (Nellis and Klein,
2008, pg. 645)
Calculating Surface Temperature
Region of aluminum between channels is treated as a one dimensional din with an
adiabatic tip.
Fin parameter: (Harms et al. 1998)

mh ch=

2h
h
w fin k al ch

NEW
Fin Efficiency

mh ch=

2h
h
k w fin ch

Solution for straight rectangular surface

Fin efficiency for a constant cross-sectional area fin with an adiabatic tip (Nellis and
Klein, 2008, pg. 106)

fin =

tanh (mhch )
mhch

Array of fins on a base.

A tot = A s ,b n A c ,b +n A s , fin
Equation for Prime surface area

Overall surface efficicnecy, in terms of prime surface area, number of fins, surface
area of fins, and fin efficiency

o =1

N fin A s , fin
(1n)
A tot

Total fin array resistance

Rconv ,tot =

1
o h Atot

Conduction resistance of skin and epoxy

Rcond =

t
k whx l hx s

Roverall =Rconv ,tot + Rcond ,base + Rcond , epoxy

T s=q R overall +T m
45 m channel width
100 m fin thickness
273 channels
Ts = 49.37 C (not including conduction of power amplififer
P = 62.42 kPa
Comments
Will provide top skin surface with < 50 degrees C
Manufacturing will be difficult as such a large aspect ratio.
Theoretical model does not predict hot spots
Neglecting viscous dissipation should not be overlooked
Burst pressure requirement not yet validated.
From energy balance, fluid outlet temperature will always be 44.69 degrees C
unless there is an increase in flow rate or reduction in inlet temperature. Will not be
able to accomplish 40 degreed C target.