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Research Papers: Design and Analysis

Mechanical Expansion of Thick-Walled Microgroove Tube for High Pressure ACR System

[+] Author and Article Information
Ding Tang1

School of Mechanical Engineering, State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai 200240, Chinatangding@sjtu.edu.cn

Dayong Li, Yinghong Peng, Zhaohui Du

School of Mechanical Engineering, State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai 200240, China

1

Corresponding author.

J. Pressure Vessel Technol 133(2), 021202 (Jan 31, 2011) (7 pages) doi:10.1115/1.4002257 History: Received April 26, 2008; Revised July 18, 2010; Published January 31, 2011; Online January 31, 2011

This paper presents a study on the expansion process, which joins fins to thick-walled microgroove tubes for high pressure air conditioning and refrigeration (ACR) heat exchanger. Experiments of the tube expansion process have been carried out. An FE model with explicit algorithm is established to study the forming quality of the tube and a novel FE model with implicit algorithm is developed to investigate the local tube-fin joining status. Evaluation of the joining quality along the longitudinal axis of the tube is tried. Both FE and experimental results show that in longitudinal section, tube-fin contact is far from full contact status and internal gaps are observed. Accordingly, process parameters and expanding die geometry are examined. Results show that among the processing factors, the expanding ratio is the major factor influencing the joining status and comprehensively beneficial range of the expanding ratio is discussed.

Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Tube expanding process

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Figure 2

Groove configuration

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Figure 3

FE model with explicit algorithm

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Figure 4

Experiment equipment: (a) platform and (b) specimen

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Figure 5

Varying of driving force in forming process (Rf=13 mm)

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Figure 6

Effect of the K and Rf on forming qualities: (a) wall thinning and (b) groove height reduction

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Figure 7

Effect of the geometry factors on driving force

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Figure 8

Axial-symmetry FE model

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Figure 9

Flow chart of numerical-experimental method

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Figure 10

FE model of the pressing experiment on the material testing machine

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Figure 11

Comparison of the two FE results: (a) upper layer modeled with normal material model and (b) upper layer modeled with Gurson material mode

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Figure 12

Section of the grooved layer before and after pressing

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Figure 13

Fin collar formed at different expanding ratio: (a) 4.79%, (b) 6.16%, and (c) 7.53%.

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Figure 14

Preparation of the specimen

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Figure 15

Fin collar formed at different expanding ratio: (a) 4.79%, (b) 6.16%, and (c) 7.53%

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Figure 16

Comparison of profiles of fin collar’s contact surface

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Figure 17

Contact pressure: (a) distribution along the fin section and (b) average contact pressure

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Figure 18

Effect of expanding ratio on fin pitch: (a) K=3.42%, (b) K=6.16%, and (c) K=7.53%

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