Computer simulation analysis on the machinability of alumina dispersion enforced copper alloy for high performance compact heat exchanger

Feasibility study on a HTGR-GT (High Temperature Gas cooled Reactor-Gas Tur bine) system is examining the application of the high strength/high thermal conductivity alumina dispersed copper (AL-25) in the ultra-fine rectangle plate fin of the recuperator for the system. However, it is very difficult to manufacture a ultra-fine fin by large-scal e plastic deformation from the hard and brittle Al-25 foil. Therefor, in present study, to establish the fine fin manufacturing technol ogy of the AL-25 foil, it did the processing simulation of the fine fin fir st by the large-scale elasto-plastic finite element analysis(FEM) and it es timated a forming limit. Next, it experimentally made the manufacturing equipment where it is possib le to do new processing using these analytical results, and it implemented a manufacturing experiment on the AL-25 foil. With these results, the following conclusion was obtained. (1) It did the processing simulation to manufacture a fine rectangle fin (f in height x pitch x thickness, 3 mm x 4 mm x 0.156 mm) from AL-25 foil (Thi ckness = 0.156 mm) by the large-scale elasto-plastic FEM using the double a ction processing method, As a result, the manufacturing of a fine rectangle fin found a possible thing in the following condition by the double action processing method. It made that 0.8 mm and 0.25 mm were a best value respe ctively in the R part and the clearance between dies by making double actio n processing examination equipment experimentally and implementing a manufa cturing examination using this equipment. (2) It succeeded in the manufacturing of the fine fin that the height x pit ch x thickness is 3 mm x 4 mm x (0.156 mm It 0.001mm) after implementing a fine rectangle fin manufacturing examination from the AL-25 foil. (3) The change of the process of the deformation and the thickness by the p rocessing of the AL-25 foil which was estimated by the large-scale elasto-p lastic FEM showed the result of the processing experiment and good agreemen t, This way of analyzing made an effective thing clear as the processing estim ation of the manufacturing practicalizing of the fine fin of the difficulty process-ability material by the double action processing method from this study.