Topology optimization of manifold fluid channel design with mass flowrate control

Topology optimization for flow problems has garnered considerable interest recently across various applications, including enhancing the efficiency of energy systems through optimized energy, momentum, and heat transfer. Conventional design methods typically rely on parametric models, which may limit the discovery of novel conceptual designs and their interconnections. In contrast, topology optimization offers a pathway to generate novel configurations of these components, aiming to enhance their efficiencies and ensure target flow distribution—an essential factor in optimizing the performance of energy system components. In this study, a topology optimization framework is proposed to address the multi-outlet problem with mass flowrate control. The objective function is normalized power dissipation, which can also be considered as pressure drop. The control includes both volume control and mass flowrate control. The mass flowrate control for each outlet is defined with lower and upper limits, set at 1% below and above the target mass flowrate, respectively. For cases with Reynolds numbers of 100, 300, and 500, the mass flowrate control across six outlets achieves an average control accuracy of 99.02%, which is within a reasonable range for the control target. The proposed method shows potential for application in heat exchanger systems to improve energy efficiency.