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COVID-19: How WIDIA is responding

Heat Exchanger Machining Solutions


Medical

What is a Heat Exchanger?

A heat exchanger is a device built for efficient heat transfer from one medium to another. The medium are separated by a solid wall so that they never mic, of the media are in direct contact

Heat Exchange Diagram


Tube sheet

Tube Sheets

The tube sheet is one of the main components in a shell & tube heat exchanger.

Depending on the tube bundle configuration, a heat exchanger can be equipped with one or two tube sheets.

These are usually made of low carbon steel material, with a varying thickness based on the fluid pressure.

Depending on the final application (petrochemical, nuclear, oil&gas, etc.) the tube sheet can be cladded with Stainless Steel or other Super Alloy or even be entirely made out Stainless Steel or Superalloys.

TOOLING SOLUTIONS

Typical Hole Patterns

The most common types of holes experienced in tube sheet drilling are triangular, rotated triangular, square and rotated square. Each hole pattern presents its own drilling challenges. See typical pattern types below. 

Triangular Pattern

Triangular Pattern

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Triangular Tube Sheet Pattern Example

Triangular Tube Sheet Pattern Example

Rotated Triangular Pattern

Rotated Triangular Pattern

Rotated Triangular Tube Sheet Pattern Example

Rotated Triangular Tube Sheet Pattern Example

Square Pattern

Square Pattern

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Square Tube Sheet Pattern Example

Square Tube Sheet Pattern Example

Rotated Square Pattern

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Rotated Square Tube Sheet Pattern Example

Rotated Square Tube Sheet Pattern Example

    

Material Configuration

Possible Material Configuration
Possible Material Configuration
Possible Material Configuration


baffles

Baffles

The baffles are thin plates positioned for the entire length of the tube bundle.

They have two primary functions:

  • Sustain the tube bundles
  • Increase the heat-transfer by changing the flow of the fluid and generating turbulence

Buffles have generally a thickness between 10mm to 20mm and they are usually machined in stacks of 2 to 5 plates, making the drilling operation more complex.

TOOLING SOLUTIONS

Typical Baffle Geometries

Single Segmented Baffles

Single Segmented Baffles
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Single Segmented Baffles

Double Segmented Baffles

Double Segmented Baffles
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Double Segmented Baffles

Disc and Donut Baffles

Disc and Donut Baffles
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Disc and Donut Baffles

Baffle Drilling

  • Baffles are generally drilled in stacks from 2 - 5 plates
  • Single plate thickness vary from 10mm - 20mm 
  • Welding the plates together can increase stability

Challenges in Baffles Drilling: 

  • Uneven surface
  • Space between the plates
  • Instability
  • Disc generated at the hole exit between the plates
     
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Proven Machining Operations

Drilling

Tubesheets have different sizes and a series of hole is done to create a place where the tube ends are welded.

Depending on the hole size and plate material, WIDIA can cover this application with TDMX, TC4 and VariDrill

Drilling of Stacked Plates

Baffles are generally machined in stacks of 2 to 5 plates. Common material is low carbon steel. To face this application with confidence WIDIA offers the TDMX Modular Drilling platform, in combination with the flat bottom insert geometry FPE

Hole Finishing

In case is needed WIDIA is capable to cover the fine finishing operation with the TRF / TRM product series 

Turning

To remove the surface impurity on tube sheets, these are machined with a turning operation. WIDIA offers a wide range of Heavy duty inserts, as well as ISO turning inserts to cover all the most common materials

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Tooling Solutions

TDMX

Extra stable pocket seat design enables high feedrates even in though coonditions, resulting in an increase of productivity and cost per hole reduction

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TC4

Versatile Indexable drilling platform covering a wide range of material and applications

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VariDrill

Universal Solid Carbide Drilling portfolio, suitable for Steel, Stainless Steel and Super Alloys

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TRF / TRM

New brazing technology enabling higher feed rates and longer tool life

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ISO Turning Inserts

Greater wear resistance in Steel, Stainless Steel and Super alloys

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Interested in learning more about our Energy tooling solutions designed for your application?

Talk to one of our WIDIA experts to discuss our metal cutting tooling options.
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