An Innovative Methodology to Design Gyroid Heat Exchangers for Metal Additive Manufacturing

Abstract

This methodology demonstrates the innovative potential in the design and production of compact heat exchangers by combining metal additive manufacturing and advanced engineering software, nTopology. The study aims to offer a modern enhancement to traditional 'Shell and Tube' type heat exchangers. Thanks to implicit modeling and parametric design features, complex internal structures of the gyroid type can be designed for such heat exchangers. The most striking aspect of the methodology is the complete automation of the design process. This is achieved by consolidating specified geometric parameters into a single function block, thereby enabling a fast and flexible workflow. Gyroid structures with high thermal performance and fluid dynamics can be optimized for various volumes and geometries. These structures can improve the overall efficiency of heat exchangers and offer significant advantages, especially for specialized application areas such as aerospace and space industries. In the design of the complex internal structure, special geometric parts called 'baffles' are also included to prevent the mixing of fluids. These parts are seamlessly integrated into the automated design process, enhancing the overall automation performance. Geometric parts are dynamically linked with other design parameters like pipe diameter, plenum area, and gyroid interface. During the design process of the gyroid heat exchanger, attention must be paid to the tolerances of metal additive manufacturing and the design principles for additive manufacturing. The heat transfer coefficients of materials like aluminum and copper alloys can be decisive in the effectiveness of the design. Therefore, it is of critical importance to consider material selection and manufacturing tolerances during the design process. In conclusion, this study shows that additive manufacturing and advanced engineering software can create a synergistic effect in the design and production of heat exchangers. To reach the maximum level of this effect, factors such as manufacturing limitations and material selection need to be carefully considered.