Why do convective-surface heat fluxes in Simulation not match hand calculations? My hand calculation is based on the reported surface temperature, the known bulk temperature, and the film coefficient.

The surface heat flux being reported is not really the heat flux at the surface but the heat flux at the centroid of the tetrahedron elements adjacent to the surface. In ANSYS Mechanical APDL, you would be able to use the ETABLE item HFCTOT for the SURF152 elements on the surface to check this.

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