Thermal Management Consulting Services

SimuTech Group provides thermal modeling consultancy services for both solid and fluid systems, as well as for interactions between these systems. We have expertise simulating fluids, metal, composite, and polymer components’ thermal behavior.

Thermal Analysis Simulation

Managing Thermal Stress

Finite element analysis (FEA) studies frequently focus on the thermal response. In multi-physics thermo-mechanical simulations, thermal analysis can be integrated with mechanical analysis to provide detailed temperature and heat-flow mapping.

Modern engineering is increasingly focusing on thermal management, particularly in light of the ongoing push toward electrification.  Temperature is frequently the primary analytical focus for engineering applications such as batteries, heaters, heat exchangers, gas turbines, etc.

Moreover, forces generated by thermal expansion can be significant and proper analysis techniques need to be implemented.  As most engineers are well-aware, accurate prediction of temperature distributions is critical to performing a thermal stress analysis.


Thermal-Structural Capabilities

Our simulation capabilities primarily focus on fluid flows caused by thermal gradients and thermal-structural interaction.

In addition, complex thermodynamic analysis for medical devices, including radio frequency (RF) tissue ablation, microwave tissue ablation, and tissue damage, is another area of expertise for SimuTech Group.


Our Thermal Engineering services include:

  • Optimization of thermal response and heat transfer efficiency
  • Accurate conjugate heat transfer (solid/fluid) simulations
  • Simulating complex flow patterns of thermal packaging
  • Thermal analysis of polymers, composites, and metals
  • Chemical reaction dynamics & phase change analysis
  • Analysis and enhancement of heating/cooling devices
  • Analysis of thermally induced failures
  • Thermogravimetric analysis (TGA)

Conduction, forced convection, natural convection, internal (cavity) radiation, radiation in participating media, phase change, natural and forced convection, thermal stresses, and conjugate heat transfer are all thermal analysis problems that we handle.


Recent Thermal Management Consulting Projects | FEA-based Solutions

Power Generation Ducting Structure

Combined CFD with FEA to predict temperature distributions on high temperature ducting internal support structure .

Ammonia Plant Outlet Header Thermal Failure Investigation

Analysis of ammonia plant outlet header assembly to investigate cracking of pipe lining refractory.

Battery Charging Case

Thermal analysis of battery charging case accounting for internal radiation and varying environmental conditions.

High Voltage Switch

Combined electromagnetic / thermal analysis of switch to account for joule heating.

Thermoelectric Generator

Transient response of energy harvesting system.  Thermoelectric Power Generation (TEG) of 14.4v unit analyzed, and enhanced.

Computer Chips

Determination of temperature distribution and heat flux with varying environmental conditions.

Electronics Enclosure

Determination of temperature curves during high and low power settings with device charging.

Power Plant Tube Wall Shielding Plate

Optimization of design to maintain temperatures and stresses in defined acceptable range.

Power Generating Device

Thermal optimization via electronics cooling simulations using conjugate heat transfer.


Untangling Phase Change & Chemical Reaction Dynamics

Complex geometry and physics, such as numerous phases, conjugate heat transfer, radiation, and turbulence, are frequently present in chemically reacting systems.

This complexity necessitates a focus on speed without compromising accuracy. Through a broad collection of reactive flow models and numerical techniques, cutting-edge meshing algorithms, and automated workflows, our preferred program, Ansys Chemkin Pro, excels in this regard.

Additionally, intricate chemistry models for accurate species predictions, flamelet models for quick and precise flame-front predictions, and chemical equilibrium models for the quickest forecasts are some of the specific techniques we frequently employ. We have experience with specialized models, such as those used to forecast emissions like CO, GHG, AZLH, AALH, ARLH, AMLH and NOx, as well as adaptive meshing for improved accuracy.

Moreover, our simulations routinely include impacts of radiation and environmental variables together with conjugate heat transfer through nearby solids.




Transient Thermal Analysis of Heat Sink Fin in a CPU Processor

The temperature at which the junction functions has a significant impact on the dependability of electronic components.

Designers must reduce the size of the entire system in order to extract heat and regulate temperature, which is the main focus of studies on electronic cooling. An ANSYS commercial package is used by SimuTech Group engineers to conduct such thermal analysis’.  Moreover, for enhancing thermal performance, geometric factors and heat sink design are often tested.  Thermal analysis’ are used in consulting projects to find cooling solutions for a desktop computer, amongst other devices, with varying wattage.  The system may be adequately cooled by the design, which can cool the chassis with a heat sink connected to the CPU.

Heat Sink Fin Modeling and Analysis in Thermal Management Consulting

Each simulation’s work flow centers around and/or considers the following:

  • The creation (reception) of a 3D model
  • The preparation of the model, including the removal of poor geometry
  • Simplification of unneeded pieces/components, and the improvement of contact zones before importing it into an FEM software
  • Basic ANSYS Workbench inputs. This information will describe the behavior of the parts during analysis and enable the model to function effectively during simulation.
  • Inputs for FEM. These variables will regulate the simulation’s calculation time and result correctness. To define them, a specific examination of the factors is carried out.
  • Simulation is performed by the program.  See Ansys Maxwell.
  • Before publishing the results in a report for everyone to see, the results are checked for statistical accuracy and significance.

With Ansys’s capabilities in conduction, convection, radiation, temperature dependent material models, and internal heat generation, complex systems can be accurately simulated.   These can be further advanced by performing FSI with a CFD model.