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Heat
Exchanger Innovation
New metal forming method offers unbeatable accuracy and repeatability
FluidForming , a sheet metal hydroforming process , is revolutionizing heat exchanger manufacturing with its remarkable 99.996 % first-pass yield rate . This article explores the impact of FluidForming as a precise and efficient solution for the industry .
By Char Vandermeer , Technical Writer
Manufacturers of heat exchangers have grappled with high tooling costs , non-conforming part waste , springback , and labor-intensive post-production procedures . These challenges not only incur substantial costs but also hinder efficiency and product quality . Overview : FluidForming sheet metal hydroforming provides a new solution to an old problem . FluidForming is a sheet metal hydroforming process that achieves a 99.996 % first-pass yield rate , providing the accuracy and repeatability that precision-driven industries need . A reinvention of conventional hydroforming , FluidForming uses extremely high forming pressures to form geometrically complex parts , like heat exchangers . Problem : Significant springback and excessive downstream costs . High tooling costs , non-conforming part waste , springback , and time-consuming post-production work have long plagued manufacturers of heat exchangers .
Solution , part I : Design improvement The FluidForming metal forming process virtually eliminates these costly issues . Before forming heat exchangers , engineers at the company use finite element analysis ( FEA ) and simulation software enables the product team to evaluate the part design prior to tool build . This lowers tooling development costs and , because only one tool is needed , overall tooling costs are also reduced . The company ’ s engineers begin with an evaluation of the
Conventional heat exchanger . Image courtesy of FluidForming Americas .
customer ’ s existing design . Using FEA , they identify areas where heat exchangers can be improved and optimized for the FluidForming process – prior to production . Ultimately , this step saves time , lowers costs , and helps ensure even material flow . Even material flow minimizes – or eliminates – stretching or tearing .
Solution , part II : Higher forming pressures Once the part design has been optimized and approved , FluidForming ’ s high forming pressures ( up to 60,000 psi ) yield parts with minimal springback or warping . With a 99.996 % first pass yield success rate , the FluidForming metal forming process can provide the quality , accuracy , and repeatability manufacturers of heat exchangers require . Additionally , because only one surface of the heat exchanger is subjected to the flexible and self-adjusting tool surface ( recycled water ), the resulting parts are free from scratches , dents , or burrs . Furthermore , because of the negligible distance between the tool and metal surface , highly complex parts can be formed with greater accuracy and repeatability than legacy methods afford . Because completed heat exchangers experience virtually no warping or springback , expensive and time-consuming post-forming fixturing and clamping is minimized or eliminated . The process can help manufacturers move from additive welding to the highly efficient , clamp-free stacked laser welding process to complete the unit . “ Part accuracy went from no-two-parts-are-alike to Six Sigma conformance and repeatability with 0 % nonconforming product ,” said the customer ’ s VP .
Conventional heat exchanger . Image courtesy of FluidForming Americas .
Results
•• 97 % reduction in plate deflection and warping .
•• 4 / 1000 ” vs . 1 / 10 ”
•• . 0043 % failure rate .
•• 15 failures out of 350,00 units vs . 17,500 .
•• 350,000 parts formed w / no tool maintenance .
•• Downtime eliminated .
•• Post-process fixturing costs eliminated .
••
Uses recycled tap water , produces no emissions or harmful waste .
40 Heat Exchanger World June 2024 www . heat-exchanger-world . com