Conjugate Heat Transfer Simulation for Power Electronics

The push toward higher power density in EV traction inverters is creating thermal loads that can no longer be approximated. Conformal interfaces, thin-solid meshing, narrow fluid passages, and node-to-node matching between dissimilar domains have become non-negotiable. This ebook walks through a complete CHT workflow built around ANSA for preprocessing and META for post-processing, with concrete examples from a single-phase power module on a finned heatsink.

What you'll take away

• Conformal interface generation across solids and fluids, including automatic contact detection through the Flanges Compatible tool, with node-to-node matching that minimizes numerical error at heat-flux boundaries.
• Feature-aware meshing for thin parts and narrow gaps, using the Thin Mesh algorithm for ribbons, IGBT dies, and DBC layers, plus Hexa Interior for accelerating bulk-volume solutions without sacrificing fidelity.
• Mesh-type selection by physics, with guidance on when polyhedral cells outperform tetrahedra in complex coolant paths, and when hex-dominant meshing wins for buoyancy-driven natural convection in the surrounding air domain.
• Automated handling of proximity and concave regions, so boundary layer coverage remains intact in the tight clearances between heat pins and the cooling bed.