不锈钢三维整体外翅片管的滚压—犁切/挤压成形及强化传热性能研究
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摘要
随着能源消耗的日益增加，世界能源日益紧张，节能减排在工业中应用越来越广泛。以第三代传热技术为基础的三维整体式外翅片管，具有较优的强化传热性能，受到越来越多的重视。对其强化传热性能和制造方法的研究，已变得越来越重要。研究表明，目前三维整体外翅片管的制造具有较大的难度，特别是以适应恶劣工况的不锈钢作为基管，其加工难度更大，基于此现状，开发了新型的犁切/挤压刀具，采用滚压-犁切/挤压复合成形方法，在不锈钢管上加工出较优的三维整体外翅片管结构。主要研究内容如下：
（1）不锈钢二维螺旋状沟槽结构的滚压加工
采用滚压成形方法在不锈钢光管上加工出不同结构的二维螺旋状沟槽，通过实验研究了滚压速度、进给量的合理选择范围，研究了不同的滚压深度条件下的二维螺旋状沟槽形貌，确定形成单一螺旋状沟槽结构的合理参数。
（2）新型犁切/挤压刀具的开发
在现有犁切/挤压刀具的基础上，根据犁切/挤压成形机理，开发出一种结构简单的新型犁切/挤压刀具，并建立了刀具的几何模型和数学模型，确定了刀具的各几何参数之间的相互关系；并针对犁切/挤压刀具的特点，采用微单元刀具法，确定了犁切/挤压临界进给量以及极限切削深度和刀具几何参数之间的关系，并通过以上关系来优化刀具结构。
（3）不锈钢管犁切/挤压成形研究及参数优化
通过犁切/挤压成形方法，在不锈钢二维螺旋状沟槽结构上制造出三维整体外翅结构。根据大量实验结果，分析了不同加工条件下的翅片形貌；并通过单因素实验，分析了不同刀具参数和加工参数对翅片高度、厚度以及间距的影响规律；通过多因素条件下的正交实验，研究了犁切/挤压深度、进给量、刀尖圆弧半径以及主偏角对翅片高度的影响规律，获得了不锈钢三维整体外翅片管犁切/挤压过程中翅片高度的经验公式；通过犁切/挤压过程切削力实验，得到了翅片加工过程中切削力的变化规律；切削力实验结果表明，犁切/挤压过程切削力的变化幅度远远大于传统切削力，并且进给方向切削力恒为负值，这将对刀具设计具有很好的指导意义。
（4）不锈钢三维整体外翅片管的传热性能测试
以R22为制冷工质，通过对不锈钢光管和三种不同加工参数下形成的三维整体外翅片管的冷凝强化传热性能测试，通过测试结果，对不锈钢光管和三种不同加工条件下形成的三维整体外翅片管的总传热系数和冷凝强化传热系数作对比，发现三种翅片管的传热性能是光管的两倍多，可以取代不锈钢光管作为冷凝管。
With the increasing of the energy resources consumption, the energy resources in theworld is used increasingly nervously, Energy saving ana emission reduction become moreand more important in the industrial applications.The outside three-dimension integral finswhich are as the third generation heat transfer enhancement technology have excellent heattransfer performance，so it can be widely used in industrial practice. The research aboutheat transfer enhancement performance and methods of fabrication manufacture ofthree-dimension integral fins become more and more important. While the manufacture ofthree-dimension integral fins have difficulty. Especially the stainless steel tube which workin worse condition is as the base tube, the manufacture is more difficult. In this condition,base on rolling-plowing/extrusion process methods, plowing/extrusion tool is developed,Three-dimension integral fins on the stainless steel tube is successfully manufactured. Themainly research works are summarized as follows:
（1）Experiment study of rolling process on the stainless steel tube
2D spiral grooves were gained on the stainless steel tube by rolling process. Thereasonable rolling speed and feed rate were choosed, and the effect of rolling depth to thespiral grooves are researched by rolling experiment. Reasonable rolling parameters wereobtained for fabricating singed V-shape spiral grooves.
（2）Development of a new plowing/extrusion tool
Based on the exiting plowing/extrusion tool and cutting theory, a newplowing/extrusion tool was developed. Geometric and mathematic model were establishedand the relationship among the geometric parameters of plowing/extrusion tool wereensured. Based on the new plowing/extrusion tool, plowing/extrusion critical feed rate andmaximum plowing/extrusion depth are ensured by micro-units tool.
（3）Experiment study of plowing/extrusion process on the stainless steel tube andoptimization of the paremeters
The Outside3D integral fins on the stainless steel tubes were manufactured by plowing/extrusion. Finned appearance by different manufactured technology paremeterswas analyzed which were based on the experimental results; the effect regularity ofplowing/extrusion tool parameters and process parameters to the finned height、thicknessand pitch were analyzed by single factor experiment; The effect regularity ofplowing/extrusion feed rate and depth and plowing/extrusion tool nose arc radius andcutting edge angle on finned height were analyzed by multi-factor experiment; the cuttingforce experiments on plowing/extrusion process were carried out, cutting force wasobtained, the experiment results of cutting force results showed that the cutting force onplowing/extrusion process changed in bigger range than common cutting, and feed force isnegative, those have better guide meaning to the tool design.
（4）Condensation heat transfer of outside3D integral fins on the stainless steel tubes
The smooth tube and three kinds of outside3D integral fins on the stainless steel tubeswere tested at the saturated vapor temperature of39℃for R22, the overall heat transfercoefficient and condensation heat transfer were compared. The experiment results wereshowed that heat transfer performance of three kinds of outside3D integral fins on thestainless steel tubes is over two times higher than the smooth tube, so the outside3Dintegral fins on the stainless steel tubes can replace the smooth tube as condensation heattransfer tube.
（1）不锈钢二维螺旋状沟槽结构的滚压加工
采用滚压成形方法在不锈钢光管上加工出不同结构的二维螺旋状沟槽，通过实验研究了滚压速度、进给量的合理选择范围，研究了不同的滚压深度条件下的二维螺旋状沟槽形貌，确定形成单一螺旋状沟槽结构的合理参数。
（2）新型犁切/挤压刀具的开发
在现有犁切/挤压刀具的基础上，根据犁切/挤压成形机理，开发出一种结构简单的新型犁切/挤压刀具，并建立了刀具的几何模型和数学模型，确定了刀具的各几何参数之间的相互关系；并针对犁切/挤压刀具的特点，采用微单元刀具法，确定了犁切/挤压临界进给量以及极限切削深度和刀具几何参数之间的关系，并通过以上关系来优化刀具结构。
（3）不锈钢管犁切/挤压成形研究及参数优化
通过犁切/挤压成形方法，在不锈钢二维螺旋状沟槽结构上制造出三维整体外翅结构。根据大量实验结果，分析了不同加工条件下的翅片形貌；并通过单因素实验，分析了不同刀具参数和加工参数对翅片高度、厚度以及间距的影响规律；通过多因素条件下的正交实验，研究了犁切/挤压深度、进给量、刀尖圆弧半径以及主偏角对翅片高度的影响规律，获得了不锈钢三维整体外翅片管犁切/挤压过程中翅片高度的经验公式；通过犁切/挤压过程切削力实验，得到了翅片加工过程中切削力的变化规律；切削力实验结果表明，犁切/挤压过程切削力的变化幅度远远大于传统切削力，并且进给方向切削力恒为负值，这将对刀具设计具有很好的指导意义。
（4）不锈钢三维整体外翅片管的传热性能测试
以R22为制冷工质，通过对不锈钢光管和三种不同加工参数下形成的三维整体外翅片管的冷凝强化传热性能测试，通过测试结果，对不锈钢光管和三种不同加工条件下形成的三维整体外翅片管的总传热系数和冷凝强化传热系数作对比，发现三种翅片管的传热性能是光管的两倍多，可以取代不锈钢光管作为冷凝管。
With the increasing of the energy resources consumption, the energy resources in theworld is used increasingly nervously, Energy saving ana emission reduction become moreand more important in the industrial applications.The outside three-dimension integral finswhich are as the third generation heat transfer enhancement technology have excellent heattransfer performance，so it can be widely used in industrial practice. The research aboutheat transfer enhancement performance and methods of fabrication manufacture ofthree-dimension integral fins become more and more important. While the manufacture ofthree-dimension integral fins have difficulty. Especially the stainless steel tube which workin worse condition is as the base tube, the manufacture is more difficult. In this condition,base on rolling-plowing/extrusion process methods, plowing/extrusion tool is developed,Three-dimension integral fins on the stainless steel tube is successfully manufactured. Themainly research works are summarized as follows:
（1）Experiment study of rolling process on the stainless steel tube
2D spiral grooves were gained on the stainless steel tube by rolling process. Thereasonable rolling speed and feed rate were choosed, and the effect of rolling depth to thespiral grooves are researched by rolling experiment. Reasonable rolling parameters wereobtained for fabricating singed V-shape spiral grooves.
（2）Development of a new plowing/extrusion tool
Based on the exiting plowing/extrusion tool and cutting theory, a newplowing/extrusion tool was developed. Geometric and mathematic model were establishedand the relationship among the geometric parameters of plowing/extrusion tool wereensured. Based on the new plowing/extrusion tool, plowing/extrusion critical feed rate andmaximum plowing/extrusion depth are ensured by micro-units tool.
（3）Experiment study of plowing/extrusion process on the stainless steel tube andoptimization of the paremeters
The Outside3D integral fins on the stainless steel tubes were manufactured by plowing/extrusion. Finned appearance by different manufactured technology paremeterswas analyzed which were based on the experimental results; the effect regularity ofplowing/extrusion tool parameters and process parameters to the finned height、thicknessand pitch were analyzed by single factor experiment; The effect regularity ofplowing/extrusion feed rate and depth and plowing/extrusion tool nose arc radius andcutting edge angle on finned height were analyzed by multi-factor experiment; the cuttingforce experiments on plowing/extrusion process were carried out, cutting force wasobtained, the experiment results of cutting force results showed that the cutting force onplowing/extrusion process changed in bigger range than common cutting, and feed force isnegative, those have better guide meaning to the tool design.
（4）Condensation heat transfer of outside3D integral fins on the stainless steel tubes
The smooth tube and three kinds of outside3D integral fins on the stainless steel tubeswere tested at the saturated vapor temperature of39℃for R22, the overall heat transfercoefficient and condensation heat transfer were compared. The experiment results wereshowed that heat transfer performance of three kinds of outside3D integral fins on thestainless steel tubes is over two times higher than the smooth tube, so the outside3Dintegral fins on the stainless steel tubes can replace the smooth tube as condensation heattransfer tube.
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