A new methodology for detecting adhesion location in aluminum tube expansion

During the expansion forming of aluminum tube, the efficiency of heat exchanger diminishes due to the adhesion of groove and expansion ball inside the tube. Despite its importance, a limited number of researches on the adhesion problems in aluminum tube expansion have been published. This study aims to analyze the adhesion occurring during the expansion forming of aluminum tube for heat exchanger and to identify its location. For this, the method of using the statistical analysis of geometry by image processing and the slope of force measured from expansion forming was suggested. The new method discovers the adhesion location from the standard deviation of groove height measured before and after expansion of tube and the differentiation of force measured from expansion forming. To prove this method, the area with deviation of groove height above average was discovered, and it was confirmed that from the actual expansion of tube cross-sectional images, the height of some grooves was abnormally shorter due to adhesion. Also, from this method, it was confirmed that the changes in differentiation of force occurring from the expansion of the tube also include the information on adhesion location.