Abstract
The characterization and scaling of the thermal-hydraulic performances in wavy plate-fin compact heat exchanger cores, based on the understanding of physical phenomena and heat transfer enhancement mechanism is delineated. Experimental data are presented for forced convection in air (Pr = 0.71) with flow rates in the range 50 ≤ Re ≤ 4000. A variety of wavy-fin cores that span viable applications, with geometrical attributes described by the cross-section aspect ratio alpha (= S/H), fin corrugation aspect ratio gamma (= 2A/lambda), and fin spacing ratio zeta (= S/lambda), are considered. To characterize and correlate the vortex-flow mixing in inter-fin spaces, a Swirl number is introduced from the balance of viscous, inertial and centrifugal forces. It is shown from experimental results that the laminar, transitional and turbulent flow regimes can be identified explicitly by this Swirl number. The effects of Swirl number and dimensionless geometric parameters on swirl flow behavior are further investigated with numerical simulations. New correlations for Fanning friction factor f and Colburn factor j are developed with Swirl number Sw, as scaling parameters. The correlations are devised by a superposition of both enhancement components due to the surface area enlargement and flow pattern modulation. The resulting correlations covering laminar, transitional and turbulent regimes are obtained by the method of asymptotic matching. The generalized correlations can well predict the experimental data to within ±20% and ±15% of error bands for f and j factors, respectively.