Heat Exchanger Finned Plate Machining for Variable Fin Heights
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Solution Overview
Problem
Existing gas turbine engine heat exchangers face inefficiencies in thermal energy transfer due to the heating of air during compression, which reduces cooling effectiveness, and existing manufacturing methods for heat exchanger fins are complex and require precise registry for progressive amplitude changes.
Innovation Solution
A method involving securing a wave form metallic sheet to a heat exchanger plate substrate, removing peaks using electro-discharge machining or wire electro-discharge machining to create progressively changing fin heights, and securing additional sheets to the opposite face, allowing for uniform fin spacing and accommodating varying plate orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If wave form metallic sheets are secured to heat exchanger plate substrates with progressive amplitude changes, then thermal energy transfer efficiency is improved, but manufacturing complexity increases due to precise registry requirements
Solution Approach 1:
The heat exchanger is divided into multiple plate substrates, each with fin structures attached. The fin structures are segmented into individual fins with varying heights, allowing progressive amplitude changes while maintaining modular assembly. This segmentation enables precise registry to be achieved through standardized connection interfaces between plates.
Solution Approach 2:
The fin structures exhibit local quality variations through progressive amplitude changes, where fin height varies along the length of each fin to optimize thermal energy transfer at different locations. This local variation in fin height creates areas of different heat transfer efficiency matched to local thermal requirements.
2Loss of energy
If fin structures with progressive amplitude changes are manufactured using traditional methods, then thermal energy transfer is improved, but manufacturing time and precision requirements increase
Solution Approach 1:
Fin structures with progressive amplitude changes are pre-formed as integral parts of the plate substrates or pre-attached as separate components before final assembly. This preliminary formation of fins with varying heights eliminates the need for complex post-assembly adjustments and reduces manufacturing time while maintaining precise geometry.
Solution Approach 2:
Traditional mechanical methods for creating progressive amplitude fin structures are replaced with additive manufacturing or precision forming processes. These alternative methods directly create the complex fin geometries in a single operation, eliminating multiple machining steps and reducing manufacturing time while maintaining precision.
3Ease of manufacture
If uniform fin spacing is implemented across all plates, then manufacturing is simplified, but thermal energy transfer efficiency decreases due to inability to accommodate varying plate orientations
Solution Approach 1:
While maintaining uniform fin spacing for manufacturing simplicity, the fin structures incorporate local quality variations through progressive amplitude changes. Fin height varies along the length of each fin to accommodate different plate orientations and optimize thermal energy transfer efficiency at each location, combining manufacturing ease with thermal performance.
Solution Approach 2:
The fin structures utilize parameter changes in fin height (amplitude) while maintaining constant fin spacing. This parameter variation allows the same manufacturing process to produce fins optimized for different plate orientations, achieving both manufacturing simplicity and thermal efficiency through controlled geometric parameter changes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances thermal energy transfer efficiency by ensuring uniform fin spacing and accommodating progressive changes in plate orientation, simplifying manufacturing and assembly while maintaining precise registry between fins.
Implementation Method 1
removing peaks using electro-discharge machining or wire electro-discharge machining to create progressively changing fin heights
Implementation Method 2
the transfer of thermal energy from a flow (heat donor flow) diverted from an engine core flow to a bypass flow (heat recipient flow)
Data Source
AI summary
A method for forming a heat exchanger plate includes providing a precursor having a body with a first face and a second face opposite the first face and at least one internal passageway; and pluralities of first and second fin precursors respectively protruding from the first and second faces. First and second fin height profiles are formed by removing material from the respective fin precursors via wire electro-discharge machining.