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BY: SADHANA MINJ
ROLLNO:1751304001
DEPT: ME(AUTO)
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
CORE
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
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
HEADER MANUFACTURING PROCESS
Raw Material
(Aluminium Sheet)
Cutting Operation
Piercing
Operation
Bending
Operation
Header
SHEET METAL OPERATION
Video: https://www.youtube.com/watch?v=JF7k5lCm1K8
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 -The 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).
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
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
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
Step 4: Light lamp Testing of Radiator:
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
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.
WITHOUT ASSEMBLY WITH ASSEMBLY
Manufacturing of radiator

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Manufacturing of radiator

  • 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
  • 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 (Aluminium 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 -The 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.