56
M
arch
2014
Aluminium round
and PFC tubing
PARALLEL flow condenser (PFC), multi
port extrusion (MPE), micro-channel
and multi-void are all names given to a
type of aluminium tube in great demand.
These flat aluminium tubes are
generally used in the automotive
industry for the production of heat
exchangers, condensers, evaporators,
radiators, oil coolers, heater cores
and CO
2
applications. The tubes
offer high corrosive resistance, good
heat conductivity and high pressure
resistance, and are cost effective if
extruded from a standard aluminium
rod. The tubes are extruded in various
different sizes and alloys in accordance
with standard specifications and
regulations.
The
automotive
industry
is
continuously seeking and developing
more efficient parts to achieve a lighter
vehicle and lower CO
2
emissions.
Aluminium round and PFC tubing are
playing a large part in achieving these
goals.
BWE Ltd is a British engineering
company specialising in continuous
extrusion machines (Conform™ and
Conklad™) and cold pressure welders
for many different applications.
Conform and Conklad are established
continuous extrusion technologies in
the non-ferrous, cable
and tube industries.
Typical
applications
include copper and
aluminium rectangular
wire (magnet wire for
transformers),
solid
aluminium
conductor
(SAC
for
cables),
copper bus bar, trolley
wire and other shaped conductors, AS
wire, OPGW, CATV, round refrigeration
tube and multi-channel PFC tubes in
different alloys.
A new Conform S315i model has been
specifically designed to extrude either a
round or multi-channel PFC tube from
the same aluminium rod (9.5mm, 12mm
or 15mm diameter). One customer
purchased a total of ten lines from BWE
specifically for this application.
With simple tool changes, the same
machine is capable of extruding solid
aluminium or copper conductors,
making it a very flexible machine.
BWE has production experience of a
wide range of PFC sizes (10 to 105mm),
hole shapes (round, square, triangular,
with internal fins), and alloys (1000
series, 3000 series and special alloys).
With the introduction of the company’s
Induction Heated Tooling System,
production efficiency has improved. A
reduced pre-heat time and a constant
high temperature are possible, which in
turn reduce the risk of thermal damage
to the delicate and complex mandrel
during start-up.
TheConformprocess offers lowcapital
and running costs, high output, high
product quality and short changeover
times. The product has excellent surface
finish, high dimensional tolerances and
fine, even grain structure. Conform is a
continuous extrusion process and has
very stable running conditions, enabling
the mechanical properties of the product
to remain consistent, with no variation
along its length.
BWE Ltd
– UK
Fax: +44 1233 630670
Email:
Website:
BWE Conform lines in production
for PFC and round aluminium tubes
Technology News
FEM analysis opens possibilities
of cold roll forming
FORMATION of ERW pipe involves
complex three-dimensional plastic/
elastic deformations. There is a limit on
the understanding of such processes of
deformationbehaviours,stressandstrain
solely relying on skills of experienced
workers. It is also impossible to evaluate
a mill design unless actually conducting
the forming process. The optimisation
of process is difficult for these reasons,
requiring many design corrections and
modifications after building the mill.
Nakata’s proprietary 3D plastic/elastic
forming analysis system allows the
scientific and theoretical understanding
of complex behaviours of steel strip
during formation. The company built
its own roll forming simulation system
to accurately predict strip deformation
under roll stress, making it possible to
optimise the forming process.
Nakata developed a forming method
using involute curvature rolls (FF rolls)
by applying FEM analysis technology.
The method not only eliminated roll
changes but also minimised influences
of diameter, material thickness and
steel type while determining the best
edge butt shape. The FFX mill can
manufacture high grade pipes such as
X80 and N80.
FEM forming analysis translates
forming loads into high accuracy data.
Optimised mechanical structure is
designed by applying FEM structural
analysis based on the data. Nakata’s
know-how is incorporated in creating
high rigidity cross beam structure for the
mills. In the new design, cross beams
in the mainframe support forming loads
that were traditionally supported by the
mill shaft. The new cross beam design
achieves high mill rigidity.
Nakata Mfg Co Ltd
– Japan
Fax: +81 6 6303 1905
Email:
Website:
