In my COMSOL conjugate heat transfer simulation with laminar flow, I modeled a 30×30×3 cm rectangular duct with water as the working fluid and a 2 mm aluminum plate on top subjected to a 1200 W heat rate. I then introduced a 2×2 turbulator array inside the duct. My expectation was that adding turbulators would increase turbulence, enhance convective heat transfer, and thereby reduce the top plate temperature. However, my results show the opposite: the average top plate temperature actually increased with the 2x2 turbulators compared to the plain duct. What could be the main issue with my simulation setup?
I would like to propose to do: review setup and boundary conditions, look accurately on flow fields, to the turbulent properties like viscous, productions, disipation and flow behaviour in general. I see only one resionable cause that is separation zones but i guess that strange results duw to numerics, mesh or others non phisical reasons.
I would re-run with a turbulence model (not laminar) and see whether the turbulator actually increases the effective heat transfer coefficient in your setup.
It is most likely due to your physics selection (laminar flow). Adding turbulators will likely change the flow regime to either transient or fully turbulent, rendering your laminar calculations invalid. Try to run your simulations with an appropriate turbulent model. Additionally, ensure that your couplings between heat transfer and fluid flow are properly calibrated.
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