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2026 Synergistic hydro-thermal performance enhancement of micro pin-fin heat sinks via improved pitch angle, perforations, and flow steering mechanisms Thermal Science and Engineering Progress
This study presents a numerical investigation into the hydro-thermal performance of a novel water-cooled heat sink featuring cylindrical spiral pin-fins designed for high heat flux management. Using ANSYS Fluent, the research was conducted in two phases. The first phase systematically analyzed the effect of the spiral pitch angle () and identified the configuration as the best geometry, yielding a Thermal Performance Factor (η) of 1.24 at Re = 500, representing a 24.0% improvement over the Simple Model (). In the second phase, various geometric modifications, including perforations and tilt angles, were applied to the optimal base model (Cases A-F). The results conclusively demonstrate that the combined modification featuring perforations and a forward tilt (Case A) achieved the maximum performance. At Re = 2000, Case A attained a heat transfer coefficient (h) of approximately , an enhancement of roughly 50.0% compared to the Simple Model. Furthermore, despite incurring the highest pressure penalty (), Case A maintained the highest overall effectiveness, recording a peak η value of approximately 1.65 at Re = 500, which translates to a substantial 65.0% improvement in thermal performance over the Simple Model. These findings provide critical design guidelines, establishing the spiral pin–fin with perforations and forward tilt as a highly effective, ready-to-implement solution for next-generation compact thermal management systems.