Three-dimensional structural analysis of the plate-fin heat exchanger

The Brazed aluminum plate-fin heat exchanger is a complex structure consisting of a core, headers and nozzles. The core is built of many layers of flat parting sheets and corrugated fins, and is sealed by side bars. Stress patterns in this type of heat exchanger have so far not been accurately analyzed, due to the complexity of the structure. A three dimensional structural analysis of such a core-header-nozzle structure subject to internal pressure is performed herein, using the finite element method, in order to investigate the mechanical characteristics of the structure. In the analysis, the corrugated fin is modeled by an equivalent anisotropic continuum element, to save on the computational cost. The adequacy of the analysis is then verified by performing a strain measurement test on the actual plate-fin heat exchanger. On the basis of the analytical results, it becomes clear that some critical parts need special attention when designing such structures.