Design and Manufacturing of Special Purpose Machine for Rolling, Insertion and Expansion of Copper Foam
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ORIGINAL ARTICLE
Design and Manufacturing of Special Purpose Machine for Rolling, Insertion and Expansion of Copper Foam Jayesh Gupta1 · Shivateja Burrala1 · Samadhan Rajgire1 · Abhijit Patil1 · Mohanish Shah1 · Pandurang Sathe2 Received: 9 June 2020 / Accepted: 31 August 2020 © Indian National Academy of Engineering 2020
Abstract A heat exchanger is usually used for transferring heat from one working fluid to another without the physical interaction of the mediums. To enhance the overall heat transfer rate between the working fluids that are in thermal contact, copper foam is to be inserted into the tube of the heat exchanger such that there is maximum positive contact between the copper foam and inner surface of the tube. However, this task is very challenging due to its low machinability as it is brittle and highly susceptible to breakage. The cycle time for manually carrying out the assembly of the copper foam and heat exchanger is 9760 s with less accuracy, leading to poor production rates. As the growth of production is eminent for any business to meet the obligations of customers, workers, and other stakeholders, the efficiency of such operations has to be improved. Hence, in the present work, we conceptualized and designed a special purpose machine (SPM) to perform rolling, insertion, and expansion operations on the copper foam in an efficient manner which cannot be carried out using conventional methods. CAD models for various components were designed on Dassault systems CATIA V5, and Finite Element Analysis (FEA) of dies and punches was carried out on ANSYS followed by manufacturing and testing. This methodology has resulted in increased overall production rates and reducing human efforts. Keywords Heat exchanger · Copper foam · Rolling · Insertion · Heat transfer · Special purpose machine · Efficiency · FEA · CAD
Introduction All mechanical and electrical devices such as automobiles, power plants and electrical utilities emit heat during their operations as a by-product. The heat so generated is dispersed to the surroundings instead of being utilized. This heat can be properly utilized for “thermally activated cooling” which involves using the waste heat for cooling
* Shivateja Burrala [email protected] Jayesh Gupta [email protected] Samadhan Rajgire [email protected] Abhijit Patil [email protected] 1
School of Mechanical and Civil Engineering, MIT Academy of Engineering, Pune, India
RTIC Thermax Pvt. Ltd., Pune, India
2
applications like air conditioning systems. Thermax India Ltd. is currently working on a project based on this principle, where heat is absorbed from the exhaust of vehicles (travel buses, cars, and vans) and that heat is used for operating the air-conditioning system of the vehicle. The project is based on absorbing and releasing heat, i.e. heat transfer from one body to the other body. To achieve this target, a sophisticated heat exchanger is to be used. There are many types of heat exchangers such as shell and tube and double pipe. In the present work, w
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