Numerical Simulation and Analysis of the Forming Process for Twisted Star-Shaped Heat Exchanger Tubes

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Abstract

Improving heat exchanger efficiency is critical for resource conservation in industries such as thermal power and metallurgy. This study proposes a novel manufacturing process for twisted star-shaped tubes, combining drawing through a profiled die with twisting to enhance heat transfer by increasing surface area and inducing flow mixing. The process overcomes limitations of traditional methods like roller forming, achieving high profile accuracy and enabling single-pass production. Finite element modeling and plasticity analysis optimized the tube profile, reducing the degree of plasticity utilization (ω) by up to 70% with a ridge-to-valley radius ratio of 1:2.2. Furthermore, the process has the potential to improve the heat transfer properties, simplifying the manufacturing, and expanding material options. This enables the use of low-plasticity materials (e.g., titanium, corrosion-resistant steels) without intermediate heat treatment, enhancing productivity and material versatility. The proposed process maximizes heat exchanger efficiency while simplifying manufacturing, offering significant potential for advanced heat exchanger designs.