Plate Fin Cutting Structure for High-Flatness Heat Exchangers
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Solution Overview
Problem
In the production of plate fin heat exchangers, poor flatness of fins can lead to compromised assembly, product quality, and heat exchange performance.
Innovation Solution
A processing apparatus with an upper die assembly, a lower die assembly, and a driving mechanism is used to cut fins with high flatness. The apparatus includes a first cutter with a first cutting edge portion and a second cutter with a second cutting edge portion, where the distance between the second cutting edge portion and the upper end portion is within the range of 0.1 mm to 0.3 mm, allowing for precise cutting and reduced burrs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting methods are used to cut fins, then the cutting process is simple and fast, but the flatness of the cut fins is poor and burrs are generated
Solution Approach 1:
The cutting process is segmented into two distinct stages: a rough cutting stage using the first cutter to separate the fin from the bulk material, and a precision trimming stage using the second cutter to achieve the final flat surface. This segmentation allows each cutter to be optimized for its specific function, with the second cutter positioned at a higher level (0.1-0.3mm above the upper die plate) to perform precise finishing without interfering with the initial cutting action.
Solution Approach 2:
The upper die plate serves as an intermediary element that coordinates the action between the first cutter and the second cutter. The first cutter cuts through the material down to the upper die plate, and then the upper die plate guides the second cutter to perform the final trimming operation. This intermediary structure ensures proper sequencing and positioning of the two cutting actions.
2Manufacturing precision
If a single cutter is used for cutting fins, then the device structure is simple, but the cutting quality and flatness are insufficient
Solution Approach 1:
The single cutting function is segmented into two specialized cutters: the first cutter positioned at the level of the upper die plate for rough cutting, and the second cutter positioned 0.1-0.3mm above the upper die plate for precision trimming. This segmentation of the cutting function into two separate tools enables high cutting quality and flatness while maintaining reasonable device complexity through clear functional differentiation.
3Manufacturing precision
If the second cutter is positioned at the same level as the upper die plate, then the structure is simple, but burrs are generated and flatness is poor
Solution Approach 1:
The vertical position parameter of the second cutter is changed from being at the same level as the upper die plate to being positioned 0.1-0.3mm above it. This parameter change transforms the second cutter from a potential source of burr generation into a finishing tool that creates a clean, flat surface by trimming the fin after the first cutter has completed the rough cutting.
Data Source
AI summary
A processing apparatus includes an upper die assembly, a lower die assembly and a driving mechanism. The upper die assembly includes a first cutter. The lower die assembly includes a second cutter and a lower die plate. The lower die plate has an upper end portion facing the upper die assembly. The second cutter includes a second cutting edge portion higher than the upper end portion. Further provided is a control method for the processing apparatus, and a heat exchanger.