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Research Papers

Experimental and Numerical Evaluation of Thickness Reduction in Steel Plate Heat Exchangers

[+] Author and Article Information
O. Onal, B. Bal

Advanced Materials Group (AMG),
Department of Mechanical Engineering,
Koç University,
Sarıyer, Istanbul 34450, Turkey

D. Canadinc

Advanced Materials Group (AMG),
Department of Mechanical Engineering,
Koç University,
Sarıyer, Istanbul 34450, Turkey
e-mail: dcanadinc@ku.edu.tr

E. Akdari

Research and Development Center,
Bosch Termoteknik Isıtma ve Klima San. ve Tic. A.Ş.,
TT-WB/EAP-Man,
Manisa 45030, Turkey

1Corresponding author.

Contributed by the Materials Division of ASME for publication in the JOURNAL OF ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received April 11, 2015; final manuscript received July 3, 2015; published online August 6, 2015. Assoc. Editor: Irene Beyerlein.

J. Eng. Mater. Technol 137(4), 041008 (Aug 06, 2015) (8 pages) Paper No: MATS-15-1084; doi: 10.1115/1.4031080 History: Received April 11, 2015

A multiscale modeling approach was utilized to predict thickness reduction in steel plate heat exchangers (PHEs) utilized in combi boilers. The roles of texture and microstructure were successfully accounted for by properly coupling crystal plasticity and finite element analysis (FEA). In particular, crystal plasticity was employed to determine the proper multiaxial hardening rule to describe the material flow during the forming of PHEs, which was then implemented into the finite element (FE) metal-forming simulations. The current findings show that reliable thickness distribution predictions can be made with appropriate coupling of crystal plasticity and FEA in metal forming. Furthermore, the multiscale modeling approach presented herein constitutes an important guideline for the design of new PHEs with improved thermomechanical performance and reduced manufacturing costs.

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Figures

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Fig. 1

Schematic describing the entire manufacturing process of the steel PHEs

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Fig. 2

(a) The pressing machine utilized in the metal-forming operation. (b) Final form of individual steel plates of a PHE upon forming operation.

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Fig. 3

Initial texture of Cu (upper image) and steel (lower image). Inverse pole figures 1, 2, and 3 correspond to normal, transverse, and extrusion directions, respectively.

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Fig. 4

The experimentally observed and predicted uniaxial tensile deformation responses of steel and Cu

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Fig. 5

(a) Heterogeneous normal stress distribution on steel plate. (b) Heterogeneous equivalent stress distribution on steel plate.

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Fig. 6

Predicted equivalent stress–equivalent strain responses of steel and Cu

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Fig. 7

(a) Experimentally determined thickness distribution for selected areas within a single steel plate. (b) Computationally predicted thickness distribution for the same selected areas in (a) within a single steel plate. The measured and predicted thicknesses of the zones indicated with circles are also tabulated in Table 2. The minimum measured (a) and simulated (b) plate thicknesses were marked with lighter font color.

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