English
Sign In
Loading Profile
No Items in Cart
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. 

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 Alloys 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

arrow
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

arrow
Square Tube Sheet Pattern Example

Square Tube Sheet Pattern Example

Rotated Square Pattern

arrow
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

Baffles 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
arrow
Single Segmented Baffles

Double Segmented Baffles

Double Segmented Baffles
arrow
Double Segmented Baffles

Disc and Donut Baffles

Disc and Donut Baffles
arrow
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 Baffle Drilling: 

  • Uneven surface
  • Space between the plates
  • Instability
  • Disc generated at the hole exit between the plates
     
divider line


Proven Machining Operations

Drilling

Tubesheets have different sizes and a series of holes are 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

If necessary, WIDIA is capable of covering fine finishing operations 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

divider line


Tooling Solutions

TDMX

Extra stable pocket seat design enables high feed rates even in tough conditions, resulting in an increase of productivity and decrease in cost per hole

View More

TC4

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

View More

VariDrill

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

View More

TRF / TRM

New brazing technology enabling higher feed rates and longer tool life

View More

ISO Turning Inserts

Greater wear resistance in Steel, Stainless Steel and Super alloys

View More

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.
Contact Us