Abstract
In this paper, the results of experimental and numerical studies on joining the thin fins to the thick base plate of a heat exchanger are presented. The elements of the heat exchanger were joined by using developed method of press forming. The joining technology consists in clamping the sheet metal into the channel of the base plate using a punch with specific geometry. The effect of different configurations of the punch geometry (shape, radius and distance between fin and punch) and the indentation depth on the depth of the interface between the fin and base plate is analysed. Furthermore, the effect of different combinations of fin-base plate materials has been numerically studied. The plate material was the AA2219 -T851 aluminium alloy, while the fins were made of the AA5251 aluminium alloy. The elastic-plastic numerical computations of the joining process have been carried out using the finite element-based MSC.Marc program. It was found that the area of the contact of the fin with the base plate can be optimised by choosing the right parameters of the tool geometry and technological parameters. Experimental research has shown that increasing the punch indentation causes the material to flow in the transverse direction to the punch and the indirect extrusion in the region between the punches.
Highlights
Many joining technologies are used to create permanent or temporary joints in the assembly of constructional elements and subasemblies
The heat exchanger fins were joined to the base plate by indenting the punch that is pressed symmetrically following the geometry of the fins
By appropriate selection of technological parameters of the joining process, i.e. the distance between the punch and the fin l and punch indentation depth, it is possible to form the suitable depth of the interface zone, which is the main parameter that influences the heat transfer between base plates and fins
Summary
Many joining technologies are used to create permanent or temporary joints in the assembly of constructional elements and subasemblies. Welding technologies cannot always be used due to the fact that they provide large amounts of heat to the connection area, which causes deformation of the structure joined [34]. The riveted and screwed joints of the sheets without usage of sealants in general do not assure the joint leak-tightness. Another method is joining by using metal forming technology which creates permanent joints and allows to joint different kinds of constructional materials [5]. This method assures the high thermal and electrical conductivity between metal-to-metal joined sheets, leak-tightness and high mechanical capacity of the joint
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