Investigation of fluid flow and heat transfer in aluminum tube hot gas forming process

In this study, hot metal gas forming of AA6063 aluminum tube is numerically studied with a focus on heat transfer of both fluid and solid phases. An experimental study is simultaneously conducted to validate the numerical results. Finite volume method has been used to discretize the governing equations. Pressure-velocity coupling of fluid phases are performed through the SIMPLEC algorithm. Some of the most important outputs of the present study are velocity distribution of fluid inside the tube as well as the fluid in the gap between tube and matrices. Because of non-homogeneous distribution of temperature on the tube surface, circulating flows are generated inside the tube which may have considerable effects on heat transfer. It is seen that after 400 s, number of the circulating flows doubles. Analysis of temperature distribution reveals that middle part of the tube reaches 500 ̊C after 600 s and other parts have higher temperature. By applying an efficient control method for heating, temperature distribution ofthe tube reaches a more homogeneous form.