Enhancement of thermo-hydraulic performance in MPF heat sink through perforations fabricated using micro-EDM drilling

A novel air-cooled perforated micro-pin fin heat sink is designed and tested for efficient heat dissipation in electronic device. The heat sink features staggered arrangement of square solid micro-pin fins (edge length = 0.7 mm) made from copper, each with two strategically placed circular perforations of 350 μm and 450 μm. These perforations are fabricated through an advanced hybrid micro-manufacturing technique that combines high-speed micro-mechanical end milling and micro-EDM drilling. A heat flux of 20 kW/m² is applied to the heat sink's base, and the resulting heat transfer enhancement and fluid dynamics are analysed with air as a coolant. The addition of two circular perforations enhances heat transfer by ≥48 % and reduces pressure drop by ≥11.84 %, primarily due to the decreased flow resistance. Experimental findings are complemented by numerical simulations utilizing conjugate heat transfer analysis to validate the operational characteristics of the micro-pin fin heat sink. This study aims to contribute to developing more effective thermal management solutions for high-power electronic devices.