Passive Mixing and Convective Heat Transfer Enhancement for Nanofluid Flow across Corrugated Base Microchannels

Vortex generators and pin fins are conventionally used to deliver fluid mixing and improved convective heat transfer. The increased pressure loss following a fractional increase in heat transfer, as well as the complex manufacturing design, leave room for improvement. The present work proposes a novel diverging–converging base corrugation model coupled with vortex generation using simple geometrical modifications across rectangular microchannels to ensure a superior performance. The Nusselt number, friction factor, and flow phenomenon were numerically studied across a Reynolds number range of 50–1000. The optimum cross-section of the microchannel-generating vortices was determined after thorough study, and base corrugation was further added to improve heat transfer. For the vortex–corrugation modeling, the heat transfer enhancement was verified in two optimized cases: (1) curved corrugated model, (2) interacting corrugated model. In the first case, an optimized curve generating Dean vortices was coupled with base corrugation. An overall increase in the Nusselt number of up to 32.69% and the thermal performance of “1.285 TPF” were observed at a high Reynolds number. The interacting channels with connecting bridges of varying width were found to generate vortices in the counter-flow configuration. The thermal performance of “1.25 TPF” was almost identical to the curved corrugated model; however, a major decrease in pressure, with a loss of 26.88%, was observed for this configuration.