Technology and experimental equipment used for the manufacture of flat parts of heat exchangers with spherical heat transfer intensifiers

Anton Novoshytskyi, Svitlana Bodu, Dmytro Fabritsyiev, Aleksandr Shumilov, Aleksandr Nikolaiev

Abstract


The improvement of heat exchange equipment is one of the key directions for increasing energy efficiency in industrial and energy systems. Technologies for manufacturing thin-walled heat exchange elements with a relief surface, which provides heat transfer intensification, are becoming particularly relevant. One of the promising solutions is the use of flat parts with spherical protrusions, the formation of which requires high accuracy and stability of geometric parameters. This study considers the technology of profiling such parts using the bending process with longitudinal tension. Unlike traditional forming methods, particularly stamping and drawing, the proposed approach reduces energy consumption, avoids residual deformations, and increases the repeatability of the profile geometry. The controlled tensile force imposed on the workpiece during the passage of the profiling rollers is a key technological factor. It has been experimentally established that the optimal result is achieved at a stress level of 85–95% of the yield strength of the material. It is in this range that a high-quality relief is formed without waviness in the zones of formation of spherical protrusions and on the edges, and the longitudinal curvature corresponds to the values 85–95% predicted by the tension correction. The design and principle of operation of the experimental equipment – the profiling unit is described, along with its technical characteristics and general appearance. The production of experimental batches of profiles on the experimental unit confirmed the possibility of manufacturing profiles with spherical protrusions by sequential local deformation under the action of longitudinal tension and clarified the technical requirements for the design of an experimental and industrial profiling unit. The proposed technology is confirmed by practical results and has the potential to be implemented in the serial production of heat exchange elements. It can be adapted to the manufacture of parts with various types of relief and used in related mechanical engineering industries, such as aviation, energy, and shipbuilding.

Keywords


heat exchangers; profiling technology; profiling with longitudinal tension; spherical heat transfer intensifiers; experimental equipment.

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DOI: https://doi.org/10.32620/aktt.2025.4sup1.21