Prof.

Pradip Dutta

Heat and Mass Transfer

Module 3, Learning Objectives:

Students should recognize the fin equation.
Students should know the 2 general solutions to the fin
equation.
Students should be able to write boundary conditions for (a)
very long fins, (b) insulated tip fins, (c) convective tip fins and
(d) fins with a specified tip temperature.
Students should be able to apply the boundary conditions to the
fin equation and obtain a temperature profile.
Students should be able to apply the temperature profile to the
Fourier Law to obtain a heat flow through the fin.
Students should be able to apply the concept of fin efficiency to
define an equivalent thermal resistance for a fin.
Students should be able to incorporate fins into an overall
electrical network to solve 1-D, SS problems with no sources.

Indian Institute of Science Bangalore

Prof. Pradip Dutta

Heat and Mass Transfer

MODULE 3

Extended Surface Heat Transfer

3.1 Introduction:
Convection: Heat transfer between a solid surface and a moving fluid is governed by the
Newtons cooling law: q = hA(Ts-T), where Ts is the surface temperature and T is the fluid
temperature. Therefore, to increase the convective heat transfer, one can

Increase the temperature difference (Ts-T) between the surface and the fluid.

Increase the convection coefficient h. This can be accomplished by increasing the

fluid flow over the surface since h is a function of the flow velocity and the higher
the velocity, the higher the h. Example: a cooling fan.

Increase the contact surface area A. Example: a heat sink with fins.

Many times, when the first option is not in our control and the second option (i.e. increasing
h) is already stretched to its limit, we are left with the only alternative of increasing the
effective surface area by using fins or extended surfaces. Fins are protrusions from the base
surface into the cooling fluid, so that the extra surface of the protrusions is also in contact
with the fluid. Most of you have encountered cooling fins on air-cooled engines
(motorcycles, portable generators, etc.), electronic equipment (CPUs), automobile radiators,
air conditioning equipment (condensers) and elsewhere.

3.2 Extended surface analysis:

In this module, consideration will be limited to steady state analysis of rectangular or pin
fins of constant cross sectional area. Annular fins or fins involving a tapered cross section
may be analyzed by similar methods, but will involve solution of more complicated
equations which result. Numerical methods of integration or computer programs can be used
to advantage in such cases.
We start with the General Conduction Equation:
1 dT

= 2T +
system

q
k

(1)

After making the assumptions of Steady State, One-Dimensional Conduction, this equation
reduces to the form:
d 2 T 
q
+ =0
dx 2 k

(2)

This is a second order, ordinary differential equation and will require 2 boundary conditions
to evaluate the two constants of integration that will arise.
Consider the cooling fin shown below:

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Heat and Mass Transfer

h,
T

Ts,
q

Ac

The fin is situated on the surface of a hot surface at Ts and surrounded by a coolant at
temperature T, which cools with convective coefficient, h. The fin has a cross sectional
area, Ac, (This is the area through with heat is conducted.) and an overall length, L.
Note that as energy is conducted down the length of the fin, some portion is lost, by
convection, from the sides. Thus the heat flow varies along the length of the fin.
We further note that the arrows indicating the direction of heat flow point in both the x and y
directions. This is an indication that this is truly a two- or three-dimensional heat flow,
depending on the geometry of the fin. However, quite often, it is convenient to analyse a fin
by examining an equivalent onedimensional system. The equivalent system will involve
the introduction of heat sinks (negative heat sources), which remove an amount of energy
equivalent to what would be lost through the sides by convection.
Consider a differential length of the fin.

h,
T

T0,
q
x

Across this segment the heat loss will be h(Px)(T-T), where P is the perimeter around
the fin. The equivalent heat sink would be 
q ( Ac x ) .

Equating the heat source to the convective loss:

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Heat and Mass Transfer


q=

h P (T T )
Ac

(3)

Substitute this value into the General Conduction Equation as simplified for OneDimension, Steady State Conduction with Sources:
d 2T h P

(T T ) = 0
dx 2 k Ac

(4)

which is the equation for a fin with a constant cross sectional area. This is the Second Order
Differential Equation that we will solve for each fin analysis. Prior to solving, a couple of
simplifications should be noted. First, we see that h, P, k and Ac are all independent of x in
the defined system (They may not be constant if a more general analysis is desired.). We
replace this ratio with a constant. Let
m2 =

h P
k Ac

(5)

then:

d 2T
m2 (T T ) = 0
dx 2

(6)

Next we notice that the equation is non-homogeneous (due to the T term). Recall that nonhomogeneous differential equations require both a general and a particular solution. We can
make this equation homogeneous by introducing the temperature relative to the
surroundings:
T - T

(7)

d dT
=
+0
dx dx

(8)

d 2 d 2 T
=
dx 2 dx 2

(9)

Differentiating this equation we find:

Differentiate a second time:

Substitute into the Fin Equation:

d 2
2
2 m = 0
dx

(10)

This equation is a Second Order, Homogeneous Differential Equation.

3.3 Solution of the Fin Equation

We apply a standard technique for solving a second order homogeneous linear differential
equation.
Try = ex. Differentiate this expression twice:

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Prof. Pradip Dutta

Heat and Mass Transfer

d
= e x
dx

(11)

d 2
= 2 e x
dx 2

(12)

Substitute this trial solution into the differential equation:

2ex m2ex = 0

(13)

Equation (13) provides the following relation:

= m

(14)

We now have two solutions to the equation. The general solution to the above differential
equation will be a linear combination of each of the independent solutions.
Then:

= Aemx + B e-mx

(15)

where A and B are arbitrary constants which need to be determined from the boundary
conditions. Note that it is a 2nd order differential equation, and hence we need two boundary
conditions to determine the two constants of integration.
An alternative solution can be obtained as follows: Note that the hyperbolic sin, sinh, the
hyperbolic cosine, cosh, are defined as:
sinh(m x ) =

e mx e m x
2

cosh(m x ) =

e m x + e m x
2

(16)

We may write:
e m x + e m x
e m x e m x C + D m x C D m x
C cosh(m x ) + D sinh(m x ) = C
+ D
=
e +
e (17
2
2
2
2
)

We see that if (C+D)/2 replaces A and (C-D)/2 replaces B then the two solutions are
equivalent.

= C cosh(m x ) + D sinh(m x )

(18)

Generally the exponential solution is used for very long fins, the hyperbolic solutions for
other cases.
Boundary Conditions:
Since the solution results in 2 constants of integration we require 2 boundary conditions.
The first one is obvious, as one end of the fin will be attached to a hot surface and will come
into thermal equilibrium with that surface. Hence, at the fin base,

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Heat and Mass Transfer

(0) = T0 - T 0

(19)

The second boundary condition depends on the condition imposed at the other end of the fin.
There are various possibilities, as described below.
Very long fins:
For very long fins, the end located a long distance from the heat source will approach the
temperature of the surroundings. Hence,
() = 0

(20)

Substitute the second condition into the exponential solution of the fin equation:

() = 0 = Aem + B e-m

(21)

The first exponential term is infinite and the second is equal to zero. The only way that this
equation can be valid is if A = 0. Now apply the second boundary condition.
(0) = 0 = B e-m0 B = 0
The general temperature profile for a very long fin is then:
(x) = 0 e-mx

(22)
(23)

If we wish to find the heat flow through the fin, we may apply Fourier Law:
q = k Ac

d
dT
= k Ac
dx
dx

(24)

Differentiate the temperature profile:

d
= o m e m x
dx

(25)

So that:
1

h P 2 m x
q = k Ac 0
e =
k Ac
where M = hPkAc .

h P k Ac e m x 0 = M 0 e mx

(26)

Often we wish to know the total heat flow through the fin, i.e. the heat flow entering at the
base (x=0).

q=

h P k Ac 0 = M 0

(27)

The insulated tip fin

Assume that the tip is insulated and hence there is no heat transfer:

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Heat and Mass Transfer

d
dx

=0

(28)

x =L

The solution to the fin equation is known to be:

= C cosh(m x ) + D sinh(m x )

(29)

Differentiate this expression.

d
= C m sinh(m x ) + D m cosh(m x )
dx

(30)

Apply the first boundary condition at the base:

0
1
(0) = 0 = C sinh(m 0) + D cosh(m 0)

(31)

So that D = 0. Now apply the second boundary condition at the tip to find the value of C:
d
( L) = 0 = Cm sinh( m L) + 0 m cosh( m L)
dx

(32)

which requires that

C = 0

cosh(mL)
sinh(mL)

(33)

This leads to the general temperature profile:

( x) = 0

cosh m( L x )
cosh(mL)

(34)

We may find the heat flow at any value of x by differentiating the temperature profile and
substituting it into the Fourier Law:
q = k Ac

dT
d
= k Ac
dx
dx

(35)

So that the energy flowing through the base of the fin is:
q = hPkAc 0 tanh( mL) = M 0 tanh( mL)

(36)

If we compare this result with that for the very long fin, we see that the primary difference in
form is in the hyperbolic tangent term. That term, which always results in a number equal to
or less than one, represents the reduced heat loss due to the shortening of the fin.

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Prof. Pradip Dutta

Heat and Mass Transfer

Other tip conditions:

We have already seen two tip conditions, one being the long fin and the other being the
insulated tip. Two other possibilities are usually considered for fin analysis: (i) a tip
subjected to convective heat transfer, and (ii) a tip with a prescribed temperature. The
expressions for temperature distribution and fin heat transfer for all the four cases are
summarized in the table below.
Table 3.1
Case Tip Condition
A
Convection heat
transfer:
h(L)=-k(d/dx)x=L

Temp. Distribution
cosh m( L x ) + ( h

cosh m( L x )
cosh mL

Adiabatic
(d/dx)x=L=0
Given temperature:
(L)= L

cosh mL + ( h

( L

Fin heat transfer

mk
mk

) sinh m( L x )
) sinh mL

Infinitely long fin

(L)=0

sinh mL + ( h

) cosh mL
mk
cosh mL + ( h ) sinh mL
mk

M 0 tanh mL

b ) sinh m( L x ) + sinh m( L x )
sinh mL

M o

M 0

(cosh mL

b )

sinh mL

M 0

e mx

3.4 Fin Effectiveness

How effective a fin can enhance heat transfer is characterized by the fin effectiveness, f ,
which is as the ratio of fin heat transfer and the heat transfer without the fin. For an
adiabatic fin:

f =

qf
q

qf
hAC (Tb T )

hPkAC tanh( mL)

=
hAC

kP
tanh( mL)
hAC

(37)

If the fin is long enough, mL>2, tanh(mL)1, and hence it can be considered as infinite fin
(case D in Table 3.1). Hence, for long fins,

kP
k P
=
hAC
h AC

(38)

In order to enhance heat transfer, f should be greater than 1 (In case f <1, the fin would
have no purpose as it would serve as an insulator instead). However f 2 is considered
unjustifiable because of diminishing returns as fin length increases.

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Heat and Mass Transfer

To increase f , the fins material should have higher thermal conductivity, k. It seems to be
counterintuitive that the lower convection coefficient, h, the higher f . Well, if h is very
high, it is not necessary to enhance heat transfer by adding heat fins. Therefore, heat fins are
more effective if h is low.
Observations:

If fins are to be used on surfaces separating gas and liquid, fins are usually placed on
the gas side. (Why?)

P/AC should be as high as possible. Use a square fin with a dimension of W by W

as an example: P=4W, AC=W2, P/AC=(4/W). The smaller the W, the higher is the
P/AC, and the higher the f .Conclusion: It is preferred to use thin and closely
spaced (to increase the total number) fins.
The effectiveness of a fin can also be characterized by

f =

qf
q

qf
hAC (Tb T )

(Tb T ) / Rt , f
(Tb T ) / Rt ,h

Rt ,h
Rt , f

(39)

It is a ratio of the thermal resistance due to convection to the thermal resistance of a

fin. In order to enhance heat transfer, the fins resistance should be lower than the
resistance due only to convection.

3.5 Fin Efficiency

The fin efficiency is defined as the ratio of the energy transferred through a real fin to that
transferred through an ideal fin. An ideal fin is thought to be one made of a perfect or
infinite conductor material. A perfect conductor has an infinite thermal conductivity so that
the entire fin is at the base material temperature.

qreal
=
qideal

h P k Ac L tanh(m L)
h ( P L) L

Tb

(40)

Tb
x
Real situation

x
Ideal situation

Simplifying equation (40):

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Heat and Mass Transfer

k Ac L tanh(m L) tanh(m L)
=
h P
L L
m L

(41)

The heat transfer through any fin can now be written as:
1
q.
= (T T
.h. A f

(42)

The above equation provides us with the concept of fin thermal resistance (using electrical
analogy) as
1
Rt , f =
(43)
.h. A f
Overall Fin Efficiency:
Overall fin efficiency for an array of fins

qf
qb

Define terms: Ab: base area exposed to coolant

Af: surface area of a single fin
At: total area including base area and total finned surface, At=Ab+NAf
N: total number of fins
Heat Transfer from a Fin Array:
qt = qb + Nq f = hAb (Tb T ) + N f hAf (Tb T )
= h[( At NAf ) + N f Af ](Tb T ) = h[ At NAf (1 f )](Tb T )
= hAt [1

NAf
At

(1 f )](Tb T ) = O hAt (Tb T )

Define overall fin efficiency: O = 1

NAf
At

(1 f )

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Prof. Pradip Dutta

Heat and Mass Transfer

q t = hAt O ( T b T ) =

Tb T
1
w here R t ,O =
R t ,O
h At O

C om pare to heat transfer w ith out fin s

1
hA
is the base area (un exposed) for the fin

q = h A ( T b T ) = h ( Ab + N Ab , f )( T b T ) =
w h ere Ab ,f

T o en hance heat transfer At O > > A

T h at is, to in crease th e effective area O At .

Thermal Resistance Concept:

L1

A=Ab+NAb,f
T1
T

Rb= t/(kbA)

T2

Tb

10

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Heat and Mass Transfer

Tb

T2

T1

Rt ,O = 1 /(hAtO )

R1=L1/(k1A)

q=

T1 T
T1 T
=
R R1 + Rb + Rt ,O

11

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Prof. Pradip Dutta

Heat and Mass Transfer

Problem 1:

A long, circular aluminium rod attached at one end to the heated wall and
transfers heat through convection to a cold fluid.
(a) If the diameter of the rod is triples, by how much would the rate of heat
removal change?
(b) If a copper rod of the same diameter is used in place of aluminium, by how
much would the rate of heat removal change?
Known: long, aluminum cylinder acts as an extended surface.
Find: (a) increase in heat transfer if diameter is tripled and (b) increase in heat
transfer if copper is used in place of aluminum.
Schematic:

q
T,h
D

Aluminum
Or copper

Assumptions: (1) steady-state conditions, (2) one-dimensional conduction, (3)

constant properties, (4) uniform convection coefficient, (5)rod is infinitely
long.
Properties: aluminum (pure): k=240W/m. K;
copper (pure): k=400W/m. K
Analysis: (a) for an infinitely long fin, the fin rate is
1

qr = M = (hpkAc ) 2 b
1

q f = (hDkD 2 / 4) 2 b =

(hk ) 2 D 2 b

Where P=D and Ac=D2/4 for the circular cross-section. Note that qfD3/2.
Hence, if the diameter is tripled,
q f (3D )
q f ( D)

3
2

= 3 = 5.2

And there is a 520 % increase in heat transfer.

Indian Institute of Science Bangalore

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Heat and Mass Transfer

(b) in changing from aluminum to copper, since qf k1/2, it follows that

k
= Cu
q f ( Al ) k Al

q f (Cu )

2 400 2
=
= 1.29
240

And there is a 29 % increase in the heat transfer rate.

Comments: (1) because fin effectiveness is enhanced by maximum P/Ac =

4/D. the use of a larger number of small diameter fins is preferred to a single
large diameter fin.

(2) From the standpoint of cost and weight, aluminum is preferred over copper.

Indian Institute of Science Bangalore

Prof. Pradip Dutta

Heat and Mass Transfer

Problem 2:

Two long copper rods of diameter D=1 cm are soldered together end to end,
with solder having melting point of 6500C. The rods are in the air at 250C with
a convection coefficient of 10W/m2. K. What is the minimum power input
needed to effect the soldering?
Known: Melting point of solder used to join two long copper rods.
Find: Minimum power needed to solder the rods.

Copper

Schematic:

D=1cm

Air
Junction
Tb=6500C

T = 250C
H=10W/m2. K

Assumptions: (1) steady-state conditions, (2) one-dimensional conduction

along the rods, (3) constant properties, (4) no internal heat generation, (5)
negligible radiation exchange with surroundings, (6) uniform, h and (7)
infinitely long rods.
Properties: copper T = (650+25)0C 600K: k=379 W/m.K
Analysis: the junction must be maintained at 6500C while energy is transferred

by conduction from the junction (along both rods). The minimum power is
twice the fin heat rate for an infinitely long fin,

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Heat and Mass Transfer

1
= 2q = 2(hpkA ) 2 (T T )
q

b
min
f
c
substituting numerical values,
1

W
W

2 2
0
q
= 210
( 0.01m) 379
(0.01m) (650 25) C.
min
m.K 4

m 2 .K

therefore,
q

min

= 120.9W

Comments: radiation losses from the rod are significant, particularly near the

junction, thereby requiring a larger power input to maintain the junction at

6500C.

Indian Institute of Science Bangalore

Prof. Pradip Dutta

Heat and Mass Transfer

Problem 3:

Determine the percentage increase in heat transfer associated with attaching

aluminium fins of rectangular profile to a plane wall. The fins are 50mm long,
0.5mm thick, and are equally spaced at a distance of 4mm (250fins/m). The
convection coefficient affected associated with the bare wall is 40W/m2. K,
while that resulting from attachment of the fins is 30W/m2. K.
Known: Dimensions and number of rectangular aluminum fins. Convection

coefficient with and without fins.

Find: percentage increase in heat transfer resulting from use of fins.
Schematic:
N=250m-1
W=width
hw = 30W/m2.K(with fins)
hwo=40W/m2.K(without fins)

L=50mm

Aluminium

Assumptions: (1) steady-state conditions, (2) one-dimensional conduction, (3) constant

properties, (4) negligible fin contact resistance, (6) uniform convection coefficient.
Properties: Aluminum, pure: k240W/m. K
Analysis: evaluate the fin parameters
t
= 0.0505m
2
A p = L c t = 0.0505m 0.5 10 3 m = 25.25 10 6 m 2

Lc = L +

L3c/ 2 (h w

/ KA P )

1/ 2

(0.0505m)

3/ 2

30 W / m 2 .K

240 W / m.K 25.25 10 6 m 2

1/ 2

L3c/ 2 (h w / KA P )1 / 2 = 0.80
it follows that, f = 0.72. hence
q f = f q max = 0.72h w 2 wL b
q f = 0.72 30 W / m 2 .K 2 0.05m ( w b ) = 2.16 W / m / K ( w b )

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Heat and Mass Transfer

With the fins, the heat transfer from the walls is

q w = Nq f + (1 Nt ) wh w b
W
( w b ) + (1m 250 5 10 4 m) 30 W / m 2 .K ( w b )
m.K
W
q w = (540 + 26.63)
( w b ) = 566 w b
m.K
Without the fins, q wo = h wo 1m w b = 40w b .

q w = 250 2.16

Hence the percentage increases in heat transfer is

qw
566w b
=
= 14.16 = 1416%
q wo
40w b

Comments: If the finite fin approximation is made, it follows that qf

(hPkAc)

1/2

b = [hw2wkwt]
overestimated.

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1/2

-4 1/2

b = (30*2*240*5*10 )

w b =2.68w b . Hence qf is

Prof. Pradip Dutta

Heat and Mass Transfer

Module 3: Short questions

1. Is the heat flow through a fin truly one-dimensional? Justify the one-dimensional
assumption made in the analysis of fins.
2. Insulated tip condition is often used in fin analysis because (choose one answer)
A. Fins are usually deliberately insulated at their tips
B. There is no heat loss from the tip
C. The heat loss from the tip is usually insignificant compared to the rest of the
fin, and the insulated tip condition makes the problem mathematically simple
3.

What is the difference between fin effectiveness and fin efficiency?

4. The fins attached to a surface are determined to have an effectiveness of 0.9. Do you
think the rate of heat transfer from the surface has increased or decreased as a result
of addition of fins?
5. Fins are normally meant to enhance heat transfer. Under what circumstances the
addition of fins may actually decrease heat transfer?
6. Hot water is to be cooled as it flows through the tubes exposed to atmospheric air.
Fins are to be attached in order to enhance heat transfer. Would you recommend
adding fins to the inside or outside the tubes? Why?
7. Hot air is to be cooled as it is forced through the tubes exposed to atmospheric air.
Fins are to be attached in order to enhance heat transfer. Would you recommend
adding fins to the inside or outside the tubes? Why? When would you recommend
adding fins both inside and outside the tubes?
8. Consider two finned surface which are identical except that the fins on the fist
surface are formed by casting or extrusion, whereas they are attached to the second
surface afterwards by welding or tight fitting. For which case do you think the fins
will provide greater enhancement in heat transfer? Explain.
9. Does the (a) efficiency and (b) effectiveness of a fin increase or decrease as the fin
length is increased?
10. Two pin fins are identical, except that the diameter of one of them is twice the
diameter of the other? For which fin will the a) efficiency and (b) effectiveness be
higher? Explain.
11. Two plate fins of constant rectangular cross section are identical, except that the
thickness of one of them is twice the thickness of the other? For which fin will the a)
efficiency and (b) effectiveness be higher? Explain.
12. Two finned surface are identical, except that the convection heat transfer coefficient
of one of them is twice that of the other? For which fin will the a) efficiency and (b)
effectiveness be higher? Explain.

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