Thermal modeling of controlled atmosphere brazing process using virtual reality technology

In the automotive industry, heat exchangers are manufactured in large quantities. The controlled atmosphere brazing (CAB) process is one of the fastest growing processes for aluminum radiator production behind vacuum brazing and machine assembly process. In this paper, we describe a thermal model (HETCAB) to predict the transient temperature distribution in an aluminum heat exchanger while it is being brazed in a CAB furnace. This thermal model is simulated using a virtual CAB (VR CAB) furnace created using virtual reality technology. Within this VR CAB furnace, engineers can “walk” through the furnace, observe the dynamic heat exchange, manipulate the products inside the furnace, and test various parameters critical to the process. The VR CAB together with the thermal model provides a realistically simulated environment that enables engineers to control and improve the heat exchange processes, experiment with design parameters, and study the effects of various process parameters including the parameters that control product yield.