3D FEM validation of ultra-small inner spiral ribbed copper tube using the tube sinking method

Abstract

This research related to the development of ultrasmall inner spiral ribbed copper tubes (ISRCTs) which have high quality and efficiency in transferring heat. The deformation behaviour of the ISRCT was studied. Three-dimensional finite element models were constructed for the various process parameters: the change of the cross-section profiles of the ribbed contours and the spiral angle of the ribbed area of the ISRCT, for twelve multi-pass drawings through the die using the tube sinking method. The effect of the ribbed spiral angle and the ribbed cross-sectional profile was also studied. Modelling and simulation techniques were performed using commercial Abaqus software to learn whether the surface profiles of the ISRCT increased or reduced with tube sinking using the finite element method (FEM). Results of the multi-pass drawing analysis were summarised and compared to the experimental findings. The FEM simulation approach was used to analyse the changes of ten parameters: von Mises stress, wall thickness, ribbed base width, ribbed tip width, ribbed base gap, ribbed tip gap, ribbed height, ribbed pitch, axial displacement and ribbed spiral angle. This procedure can be used to improve product quality and to study the effect of the various parameters. The results will be very valuable for researchers and well engineers for future design of ultra-small ISRCT to improve the quality and efficiency of heat transfer.

Review on Advances in Metal Micro-Tube Forming

“…Recent developments in the fabrication of micro-tubes aim in particular to provide improved semi-finished products, with more economic manufacturing processes, for use in microsystem-based applications of medical engineering and microfluidics for heat exchangers. When primarily considering the fabrication of seamless metallic tubes, the investigated technologies can be divided into (a) dieless drawing techniques [5,[21][22][23][24][25][26][27][28][29][30][31][32][33][34][35], (b) process chains, applying scaled-down and partly modified tube drawing [36][37][38][39][40][41][42][43][44][45][46][47], and (c) manufacturing techniques of grooved micro-tubes for applications in heat exchange [43,[48][49][50][51][52][53][54]. Apart from this research into tube manufacturing processes, notable progress was also achieved in the design of the process and tools for the profile extrusion of tubular micro-profiles with a number of channels [55][56][57][58][59].…”

“…Figure 6 illustrates the change in wall thickness for the multi-pass drawing of a grooved micro-tube with different media, as an example. Finite element models were developed for the analysis and optimization of the multi-stage sinking of straight- [53] and spiral-ribbed micro-tubes [48], considering three-dimensional forming conditions.…”

“…Figure 6 illustrates the change in wall thickness for the multi-pass drawing of a grooved micro-tube with different media, as an example. Finite element models were developed for the analysis and optimization of the multi-stage sinking of straight- [53] and spiral-ribbed micro-tubes [48], considering three-dimensional forming conditions. Achievements in the fabrication of extruded tubular profiles made from aluminum alloys with micro-channels ( Figure 7) by hot extrusion processes involved investigations that led to a deeper understanding of the microstructure evolution during extrusion and of influences on weld seam strength.…”

Research on prediction model of forming mechanical behavior of the dimpled tube based on the response surface methodology

“…They evaluated the forming limit of dimpled tubes. Tangsri and Norasethasopon 14 found that the drawing force increased with the increase in the friction coefficient by the sinking method to produce an inner spiral ribbed copper tube. Nguyen et al 15 conducted a simulation and experiment on the dimpling process.…”