Multi-objective optimization and correlation development of HPD-type perforated fins based on fluid–structure interaction analysis

•An HPD-type perforated fin is proposed.•The performance of HPD-type fins was investigated based on the FSI.•The correlations for HPD-type perforated fins were fitted based on the RSM.•The optimal parameter combinations for HPD-type perforated fins were obtained by the GRA. In this study, in combination with the flow behavior of HPD-type fins, an HPD-type perforated fin is proposed, which reduces the flow resistance by an average of 55.9% and improves the comprehensive performance by an average of 22.3%. Subsequently, the thermal–hydraulic performance and stress analysis of HPD-type perforated fins are numerically investigated based on fluid–structure interaction analysis. The findings indicate that the performance of HPD-type perforated fins is highly influenced by the fin width Fw. Moreover, the correlations were established using the RSM concerning the j, f-factor, and the maximum stress, with maximum prediction errors of 8.9%, 19.1%, and 5.8%, respectively. Ultimately, the optimized parameter combination for HPD-type perforated fins was determined through GRA, considering maximum JF-factor and minimal maximum stress as the optimization objectives. The outcomes revealed a notable enhancement in the JF-factor by 96.4% and a concurrent reduction in maximum stress by 3.7% under identical conditions. In conclusion, perforating HPD-type fins proves to be an effective strategy for enhancing both thermal–hydraulic performance and stress distribution.