Advanced Multiphysics Simulations for Optimizing Heat Transfer Performance in Thermal Engineering Systems

Abstract

This study investigated the use of advanced multiphysics simulations to optimise heat-transfer performance in thermal engineering systems. Coupled numerical models were developed to simultaneously solve the governing equations for fluid flow, heat conduction, convection, and radiation under realistic boundary conditions. Model validation was undertaken using benchmark thermal–hydraulic data, after which a structured programme of parametric simulations was conducted. The results showed that optimised design geometries and increased coolant flow rates significantly reduced maximum operating temperature and improved heat-transfer coefficients compared with the baseline configuration. However, these thermal gains were consistently accompanied by higher pressure drops, indicating an increased pumping-power requirement. The analysis also revealed diminishing temperature-reduction benefits at higher flow rates, highlighting the need for multi-objective optimisation rather than single-criterion design. Temperature contour and velocity-field analysis further confirmed that geometric refinement enhanced mixing and surface heat transfer while redistributing local hot-spot regions. The findings demonstrated that multiphysics simulation provided reliable performance insight, reduced prototype-testing requirements, and improved prediction accuracy compared with simplified design approaches. Overall, the study confirmed that optimal thermal performance existed at a balance point between heat-transfer enhancement and hydraulic penalty. The research therefore reinforced the value of high-fidelity, validation-driven multiphysics modelling as an essential decision-support tool for engineers seeking to design efficient, durable, and energy-responsible thermal systems. Recommendations and future research pathways were outlined to incorporate additional coupled physics, data-driven optimisation, and experimental validation into next-generation thermal-system design workflows.