基于CAE的平流式换热器无模成型工艺开发

Development of dieless forming process of parallel flow heat exchanger based on CAE

为实现高效的平流式换热器柔性弯曲制造,避免模具对制品的损伤,采用仿真与试验相结合的方法实现平流式换热器无模弯曲工艺开发.与传统的换热器绕弯成型技术相比,该成型过程无须弯曲模,而是通过控制换热器两端的运动轨迹实现弯曲成型,改变相应的运动轨迹能实现不同的弯曲半径.在成型原理分析的基础上,建立无模弯曲成型过程的有限元仿真模型,并基于仿真结果确定合理的弯曲速度、夹头长度和中性层半径等工艺参数.设计并制造无模弯曲成型试验装置,并研究翅片结构等因素对成型质量的影响.

To implement efficient flexible bending manufacture of parallel flow heat exchanger and avoid die damage to products, the dieless bending process of parallel flow heat exchanger is developed by the method combining simulation with test. Compared with the traditional rotary draw bending forming technique, the bending forming is implemented by controlling trajectory of the two ends of heat exchanger without bending die. Variable bending radii can be obtained by changing trajectory. Based on the analysis of forming principle, the finite element simulation model is established for dieless bending forming process, and the reasonable process parameters such as bending velocity, gripper length, neutral layer radius and so on are determined according to the simulation results. A test device is designed and manufactured and the effect factors on forming quality such as fin structure are studied.