UNIVERSITY OF ELECTRONICS SCIENCE AND TECHNOLOGY OF CHINA (UESTC)

PhD RESEARCH PROPOSAL ON COMPARISON OF THERMAL AND STRESS PROPERTIES OF LAMINATED GRAPHITE AND COPPER USING THE METHOD OF FINITE ELEMENT ANALYSIS (FEA) BASED ON ANSYS SOFTWARE

BY EDWIN OKOAMPA BOADU SCHOOL OF MICROELECTRONICS AND SOLID STATE ELECTRONICS

SUPERVISOR: PROF YUAN LIN

MARCH, 2013

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PREFACE This is a proposal for PhD project for the partial fulfilment of the requirement of school of Microelectronics and Solid State Electronics at the University of Electronics Science and Technology of China (UESTC).

In this proposal, scope and context of the project to be undertaken is provided. It gives the details of the methodology and step by step procedure in the achievement of project results. It also provides a schedule for the completion of the project, including a list of all the deliverables and presentations required.

The intended audience of this proposal is the school of Microelectronics and Solid State Electronics so that they can determine whether the project should be approved as proposed, approved with modification or other.

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TABLE OF CONTENTS TITLE Preface Table of Content PAGE 1 2

INTRODUCTION 1.0 Background 2.0 Finite Element Analysis/Model 3.0 Formal Requirements 4.0 Aims and Objectives of the study 5.0 Approach of the study 6.0 Rationale 7.0 Organization of the study 8.0 Literature Review 9.0 Parameter preparation 10.0 Timeline 11.0 Final Report 3 4-5 5 6 67 7 8 89 9 10 10

12.0 References

11 - 12

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INTRODUCTION

1.0 BACKGROUND In the electronic market nowadays is driven by the desire for increased thermal performance and function along with decreasing size of materials. New blend materials have taken the important position in engineering field. These materials fulfil the demand of almost all engineering applications maintaining tremendous mechanical and physical properties [1]. Copper Graphite composite combines the advantages of high thermal and electrical conductivity from copper and low thermal coefficient of expansion (CTE) and lubricating properties from graphite. The development of new methods in analyzing and comparing material designs by the finite element method (FEM) is of increasing importance. Engineering designers are more and more applying the growing opportunities of numerical methods to perform safety assessments for their products which require suited methods also for competency in the material sales market. This project gives an overview, computation and comparison of copper graphite laminated design within the complex field of finite element design analysis. At first, some general and more formal aspects concerning the correct finite element program selection and documentation of modelling, material properties, boundaries and calculations results including their interpretation to give a reliable basis. Secondary, the project discusses the technical questions, about complex materials laminated geometrics, particularly when the actual thermal stress limits of the materials are to be increasingly exploited for reliability purposes.

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2.0 FINITE ELEMENT ANALYSIS/METHOD (FEA/FEM) The mathematical determination of laminated graphite/copper material thermal, stress analysis can be performed either analytically or numerically. Since analytical approaches in mechanics and thermo-mechanics are generally based on very idealized assumptions. Example constant dimensions, restrains, these are no longer adequate for a sufficiently accurate calculations of complex laminated geometrics. With respect to this development today, there is the possibility to apply the finite element analysis or method (FEA/FEM) in which a real structure is mapped out as one more or less finely subdivided model structure that is meshed of the finite elements material properties, initial conditions and boundary conditions are then assigned to the quality model. The following terms are of basic importance: 2.1 Verification and validation A verification report provides evidence that the used FE model with input parameters especially material characteristic values, among others give a sufficient precise description of the technical problem that is, the investigated physical reality. This may be achieved through comparison with ascertained experimental results, or by relation with analytical solutions. 2.2 Parameter study Parameter studies would be used for the specific investigation of the effects on the results of calculations in this project, when material laws or parameters, defining of elements, boundary or constant conditions are varied for a given design, taken into account possible or feasible fluctuation conditions.

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2.3 Design calculation Design calculations would be performed in order to assess limited values within the target magnitudes of technical problems like stresses, deformations, temperatures etc. This may appear to be useful if important input parameters are only insufficiently known, and the results obtained through assumptions are within admissible areas.

3.0 FORMAL REQUIREMENTS All relevant variables thus, selection of terms, formula symbols, units, order systems etc. shall be described and defined unambiguously in this project; Numerical safety verification report shall essentially relevant for checking the results; Programme/FE code documentation and description shall include also the evidence of programme suitability, reliability. Modelling definitions of suitable mathematical model for the corresponding mechanical or thermal safety verification is essential for each numerical analysis [3]. [4]. The suitability of the used material models to the problems to be solved shall be justify in a presentation. Data documentation This shall include complete input data sets, decisive results and further results where necessary. Input data shall completely include those values required to assure independent reproduction of the FE model calculations. The input file and the output file would be included. include all information and data being

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4.0 AIMS AND OBJECTIVES OF THIS STUDY Copper graphite laminates: To analyzing the thermal and the structural properties of comparing their reliabilities using FEA technique in ANSYS; To vary the various parameters like temperature, weight/thickness, To comparing thermal stress suitability between copper and graphite; To study the thermal and shielding design and critical limits. graphite and copper and

5.0 APPROACH TO THIS STUDY The primary objective of this study is to conduct thermal and structural (stress) analysis of the composite material (graphite/copper). By knowing the extent of stress, thermal conductivity the graphite copper size in a given system, one can tell the extent to which a particular size and material that match the thermal properties, stress level.

The design will give the exact parameters for the selection of graphite copper thickness ratio according to heat dissipation required. Previously Engineers had to use expensive and heavy full copper based solutions to solve heat-spread problems.

An investigation into the relative magnitude and distribution of the normal and shear stresses within the material would be assessed.

The study will discuss strategies, alternative graphical tools and tables, and computer algorithm to help engineers plan more efficient experiments.

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A 3D finite element Analysis (FEA) model of the composite (Graphite/Copper) will be developed in ANSYS 14.0 to determine the thermal, stresses and strains. The model would be used to validate and compare the results from analytical expression.

This priority of this study is to provide tools that will ensure better designing options for graphite and copper laminates.

Desktop study and calculations will be employed using known properties of the laminated materials and geometry for each particular design.

6.0 RATIONALE Graphite /copper laminates are also of interest in the model composite system; The Gr/Cu components do not react with one another to form compound; The only bond between the fibre and the copper matrix is mechanical bond; The graphite and copper also have greatly different thermal expansion coefficients. This combination of factors makes it unique among the material laminates currently being studied.

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7.0 ORGANISATION OF THE THIS STUDY

This study will have five chapters. The first chapter will elaborate on the problem, importance, objectives of the study investigation and scope/limitations. The second chapter will give a brief information about the previous work that have been done by other researchers in this area (Literature Review). Chapter three will sequentially outline the modelling procedure and also focus on development of analytical expression for the laminated material, finally the stepwise procedure to develop the finite element model. The forth chapter will deal with the results and discussions from the study. And finally, chapter five will describe the main findings, conclusions and future work to be done.

8.0 LITERATURE REVIEW

To have an idea (Background) on the previous work done by researchers in similar field, the following papers and journals have been read so far. Below are some of the findings: S. Johnathan, S. Jinsho kim and Paul, V. Boudreaux, (2005) [2] studied performance of graphite foam evaporator for use in thermal management using the bonding method. The writer concluded based on the experimental findings that, using the graphite foam as an evaporation in a thermosyphon enables the transfer of large amount of energy relatively low temperature different and without the need of external power.

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K. Rajkumar and S. Aravindan (2009)[3] studied microwave sintering of copper graphite composite coarser microstructure with large porosity is obtained by the convectional sintering process which decreases the strength, wear resistance as well. The researchers found out that in microwave sintering process heat is generated internally within the material and the sample becomes source of heat. It was reported that, the finer micro-structure with relatively smaller and round pores, resulted due to microwave heating, enhances the performance of the composite. H. Young et al. (2010)[6] and also studied the effect of the ratio of graphite/pitch coke on the mechanical and tribological properties of copper graphite composite. Wenlin Maa and Jinjun Lu (2010)[7] studied the effect of surface texture on heat transfer layer formation and the behavior of copper graphite composite. For the purpose of this proposal, just few of the writers have been cited. 9.0 SAMPLE/PARAMETER PREPARATION TABLE The table below shows the summary of sample parameter preparation:

10.0 TIME L Ref: Copper 400W/mK

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10.0 TIMELINE 1. This proposal would be defended in a form of presentation (Date and Time by the Supervisor); 2. Acceptance & notification (Date and Time by the Supervisor); 3. Contents and chapter checks (Every Week, by supervisor); 4. Project draft and final notification of completion by December, 2013. 5. Preparation for publications of project findings (to be discussed by Supervisor)

11.0 FINAL REPORT Final document will fully describe chosen design, implementation and result of analysis detailed (ANSYS) suitable for delivery would be employed.

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12.0 REFERENCES [1] Bellcore specification, generic requirements for electronic equipment cabinets, GR 487 core, issue 1, June 1996 section 3, 29

[2] S. C. Tjong, Z. Y. Ma, Mater. Sci. Eng. 29 (2009) 49 113.

[3] Rajkumar, K., Aravindan, S., Microwave sintering of copper graphite composites, Journal of Materials Processing Technology 209 (2009) 5601 5605. [4] Baguley, D., Hose, D, R How to model with Finite Element [5] Bathe, K. J, Finite Element Method, 2. Auflage, Springer Verlag, 2002.

[6] Yang, Huijun, Luo, Ruiying, Han, Suyi, Li, Midan, effect of the ratio of graphite/pitch coke on the mechanical and tribological properties of copper-carbon composites, Wear 268 (2010) 1337 1341.

[7] Ma, Wenlin, Jinjun, Lu, Effect of surface texture on texture on transfer on wear and corrosion behavior of cu graphite composites prepared by electroforming, composites Science and Technology 67 (2007) 1210 1217.

[8] Power product selection guide, publication no. 12A 2000, Hp 10k 12/99.

[9] S. Rawal, Metal Matrix Composites for space Applications, Vol.4, No. 53, 2001, pp14 17. http://www.tms.org/pub/journals/JOM/jom.html.

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[10] S. H Avner, Introduction to Physical Metallurgy, 2nd ED, McGraw Hill, 1983.

[11] Zienkiewiez, O. C., Taylor, R. L. :The Finite Element Method, 3 Vols., 5th ed., Butterworth Heinemann, 2000 ISBN 0-7506-5160-1

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