• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.8 s.239
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• pp.1043-1050
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• 2005

Condenser tube is a component of the heat exchanger in automobile and air conditioning apparatus. It is generally made from the 1000 or 3000 series Al alloys that have good heat efficiency. In the case of 3000 series, these have high strength and hardness but have the disadvantage of low extruability. The development of extruding process in condenser tube with 3000 series Al alloys is studied in this paper. A study on extrusion process is performed through the 3D FE simulation in non-steady state and extrusion experimentation. Also, nano-indentation test is employed to estimate the weldability of tubes. Especially, An evaluation of the weldability using the nano-indentation is accomplished as compared with nano-hardness of welded part and the others in cross-section of tube.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.315-318
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• 2003

Recently, condenser tube which is used for a cooling system of automobiles is mainly manufactured by the conform extrusion but this method is inferior as compared with direct extrusion in productivity per the unit time and in the equipment investment. Therefore, it is essential for the conversion of direct extrusion with porthole die. The direct extrusion with porthole die can produce condenser tube which has the competitive power in costs and qualities compared with the existing conform extrusion. This study is designed to evaluate metal flow, welding pressure, extrusion load tendency of mandrel deflection that is affected by variation of porthole shape in porthole die. Estimation is carried out using finite element method under the non-steady state. Also this study was examined into the cause of mandrel fracture through investigating elastic deformation of mandrel during the extrusion.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.5
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• pp.66-72
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• 2003

In case of hollow cylinder extrusion using porthole die, the effects of extrusion parameters-temperature, the speed of extrusion, the shape of the die and mandrel-on metal flow in porthole die extrusion of aluminum have been investigated. However, there have been few studies about condenser tube extruded by porthole die. Original metal flow of condenser tube by porthole die extrusion is similar to hollow cylinder extrusion but the estimation of metal flow for extrusion parameters is different. For example, variation of chamber length in hollow extrusion only affects the welding pressure, however, the welding chamber length in condenser tube extrusion influences to the welding pressure as well as the deflection of mandrel. This study was designed to evaluate metal flow, welding pressure, extrusion load, tendency of mandrel deflection according to angular variation in the bottom of chamber in porthole die. Estimation was carried out using finite element method in as non-steady state. Analytical results can provide useful information the optimal design of porthole die.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.11
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• pp.44-51
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• 2007

Condenser tubes are mainly produced by precision extrusion with a porthole die and are used in the flow pass of refrigerant cooling systems in automobiles. The recent technical trend of condenser tube requires the tube to be of more multi cellizing, high strength and small size, and to increase the heat transfer area and heat efficiency. Hence, this paper is shown that the results of FE-simulation are in good agreement with the experimental ones. Finally, the extrusion die shape is proposed through analysis of FE-simulation and performance of trial extrusion. Chamber shape dimension and initial temperatures of die is adjusted analysis results. And the possibility of extrusion is estimated that forming load, welding pressure and stress analysis of die in this paper. The validity of simulated results was verified into extrusion experiments on the condenser tubes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.23-26
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• 2004

This paper describes the analysis of extrusion process and integrity for the condenser tube which is component of the heat exchanger in automobile and air conditioning apparatus. As development of the analysis method using computer, recently. It have been applied to the 3-dimensional hot extrusion process with complex section area of the non-steady statement and then results of the analysis have been applied to optimal die design and process design. As the result, this paper confirmed that used extrusion die of the research is satisfactorily designed to dimensional accuracy. And the stress point of view, condenser tube confirmed that it was influenced by the flow pressure of alternative regrigerants.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.8 s.239
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• pp.1146-1152
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• 2005

Recently, multi cell tube which is used for a cooling system of automobiles is mainly manufactured by the conform extrusion but this method is inferior as compared with direct extrusion in productivity per the unit time and in the equipment investment. Therefore, it is essential for the conversion of direct extrusion with porthole die. The direct extrusion with porthole die can produce multi cell tube which has the competitive power in costs and qualities compared with the existing conform extrusion. This study is designed to evaluate metal flow, welding pressure, extrusion load, tendency of mandrel deflection that is affected by variation of porthole shape in porthole die. Estimation is carried out using finite element method under the non-steady state. Also this study was examined into the cause of mandrel fracture through investigating elastic deformation of mandrel during the extrusion.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.397-400
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• 2004

The direct extrusion with porthole die can produce condenser tube which has the competitive power in costs and qualities compared with the existing conform extrusion. In general, porthole die extrusion has a great advantage in the forming that produces the hollow sections difficult to produce by conventional extrusion with a mandrel on the stem. Especially, condenser tube manufactured by porthole die belongs to sophisticated part and demands tighter dimension tolerance and higher surface finish than any other part. In order to confirm the general of porthole die extrusion, we perform the 3D FE analysis of hot porthole extrusion in non-steady state by using DEFORM 3D and investigate a pattern of elastic deformation for porthole die through the stress analysis using ANSYS 5.5 during extrusion process.

• Transactions of Materials Processing
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• v.12 no.3
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• pp.214-220
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• 2003

In the case of hollow cylinder extrusion using porthole die, the effects of extrusion parameters-temperature, the speed of extrusion, the shape of the die and mandrel-on metal flow in porthole die extrusion of aluminum have been investigated. There have been few studies about condenser tube extruded by porthole die. This study was designed to evaluate metal flow, welding pressure, extrusion load, tendency of mandrel deflection according to variation of chamber length in porthole die. The welding chamber height in condenser tube was calculated by using finite element method. Forming analysis results for condenser tube would provide useful information for the optimal design of porthole die.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.11a
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• pp.33-41
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• 2002

In case of hollow cylinder extrusion using porthole die, the effects of extrusion parameters-temperature, the speed of extrusion, the shape of the die and mandrel-on metal flow in porthole die extrusion of aluminum have been investigated. However, there have been few studies about condenser tube extruded by porthole die. This study was designed to evaluate metal flow, welding pressure, extrusion load, tendency of mandrel deflection according to variation of chamber length. in porthole die. Estimation was carried out using finite element method. Porthole die is analyzed in as non-steady state. Analytical results provide useful information the optimal design of porthole die.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.436-439
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• 2005

Condenser tube has been used as a component of heat exchanger in automobile and air conditioning apparatus. In this paper, porthole die extrusion that is advantageous to form long hollow section tube is analyzed by direct extrusion of condenser tube with 12 holes. A study on extrusion process is performed through the 3D FE simulation at non-steady state and extrusion experiments. Especially, weldability, extrusion load and die defects were estimated try FE-simulation. This study present the redesigned die of direct extrusion in consideration of the results obtained from FE-analysis.