Numerical simulation of the roll forming process of aluminum folded micro-channel tube

Abstract

Micro-channel tube is the most important component of flat tube heat exchangers. The folded microchannel tube is made of clad aluminum sheet through roll forming process, and has great advantage in the aspect of corrosion resistance over extruded tube. The folded tube's sub-millimeter channel size as well as tight dimensional precision requirement brings great challenge to roll forming process design. In this paper, the finite element model of the whole roll forming process of a ten-channel tube is established by using ABAQUS/Explicit. The deformation at different forming stands are investigated and compared with experiment. The hydraulic pressure test is carried out on the developed tube and its pressure bearing capacity is evaluated. © Published under licence by IOP Publishing Ltd.