This study proposes an optimal heat sink fin design for robot actuator housings under high-pressure die-casting (HPDC) constraints. Three fin geometries — straight, wave, and pin types — were evaluated using steady-state thermal analysis based on Newton's Law of Cooling. Wave-type fins achieved greater heat dissipation area than straight-type fins at equal thickness, enabling approximately 0.4 mm thinner fins and 9.4 g weight reduction under equal-area conditions. To further refine the wave geometry under manufacturability constraints, a Box-Behnken design with 26 cases was conducted across two fin-count groups (n=5, n=6). Multiple regression analysis identified fin thickness, fin count, and wavelength as factors with statistically meaningful effects on filling temperature, while fin count was the dominant factor governing thermal performance ( = −2.83 °C, p < 0.001). The results indicate that geometry-only optimization is insufficient to secure mass-production margin within current process conditions, and a combined adjustment of process parameters (melt superheat, gate area, injection velocity) is required.

Abstract
1. 서 론
2. 해석 조건 및 방법
    2.1 기하학적 모델링
    2.2 다이캐스팅 충진 해석 조건
    2.3 격자 수렴성 검증
    2.4 충진 임계 두께 규명
3. 형상 최적화
    3.1 열해석 조건 및 방법
    3.2 방열 해석 결과 분석
    3.3 Wave 형상 최적화 실험계획법
    3.4 Wave 형상 최적화 결과 분석
4. 결 론
후 기
References

• 장윤석(Graduate School of Mechanical Engineering, Kongju National University) | Jang Yun Seok
• 신동석(Graduate School of Mechanical Engineering, Kongju National University) | Shin Dong Seok
• 전의식(Division of Mechanical & Automotive Engineering, Kongju National University) | Jeon Euy Sik Corresponding author