Manufacturing of radiator

radiator in a heat exchanger its a part of engine cooling module. manufacturing of radiator and you can go through every part used to make the radiator with the different process till leak testing.

1. BY: SADHANA MINJ ROLLNO:1751304001 DEPT: ME(AUTO)

2. RADIATOR Definition Of Radiators : Radiators are Heat-Exchangers used to transfer Thermal Energy from one medium to another for the purpose of cooling and heating.function of the radiator is to transfer unwanted heat energy from the coolant to outside air. Major part of radiator Core Tank Gasket Tube Fin Header upper tank Lower tank

3. CORE

4. TUBE MANUFACTURING PROCESS Raw material (aluminium coil) Folding Operation Rolling Operation Cutting Operation Tube TUBE MILL MACHINE Video : https ://www.youtube.com/watch?v=eDRg0DOfsZA

5. FIN MANUFACTURING PROCESS Raw material (aluminium coil) Forming Operation compress Operation Cutting Operation Fin FIN MILL MACHINE Video: https://www.youtube.com/watch?v=JbL8uIaY374&t=43s

6. HEADER MANUFACTURING PROCESS Raw Material ( A luminium Sheet) Cutting Operation Piercing Operation Bending Operation Header SHEET METAL OPERATION Video: https ://www.youtube.com/watch?v=JF7k5lCm1K8

7. HOW A RADIATOR CORE IS BUILT Step 1: Layer Fins and Tubes : To being with, we stack alternating layers of fins and tubes one on top of the other. How many layers do we add? That all depends on the dimensions of the radiator being built . Fin Detail - T he fins have channels cut into them to help direct the air flow. Pictured above are fins being rolled out (left) and the fins being added to a radiator core (right).

8. Step 1: Layer Fins and Tubes : Tube Details - The standard radiator tube is a thin walled tube that stretches the length of the core. When the radiator is in use, coolant flows from tank to tank via the tubes in the core allowing it to dissipate heat through the tube walls and the fins. There is one difference between aluminium tubes and copper-brass tubes. Pictured above are tubes being added to the radiator core

9. Step 2: Attach Headers : The headers serve two purposes. First they hold the tubes and fins securely in place, and secondly, they provide a mounting point for the radiator tanks in a standard radiator. The headers are tapped into place using a rubber mallet and metal blocks so the tubes extend into the header slightly. To ensure there will be a good flow of coolant through the tube, a roller is used to open the ends of the tube. At this point, the core is nearly complete, but there is one important final step to perform. rubber mallet The tube openings being widened after the header is attached Automatic header assembly

10. Step 3: Braze the Core :(IN SIDE FURNACE) Brazing is a process where two metal pieces are joined by heating a filler metal which flows through the joint. We use a flux (chemical coating) that melts when the radiator core is sent through furnace. The result is a solid, all aluminium core that is ready for its tanks. Before After

11. Step 4: Light lamp Testing of Radiator :

12. Step 5: Ready for the tank assembly : Once the core has been brazed (aluminium) or soldered (copper-brass), it is ready to have tanks put on it (by crimping process) and be tested before it is put into service. Video: https://www.youtube.com/watch?v=qu0975CDNhM

13. Step 6: Leak testing of Radiator : Once the core has been assembled with tank, it is ready for the final step i.e. (leak testing) to ensure the radiator is leak free.

14. WITHOUT ASSEMBLY WITH ASSEMBLY