Influence of geometrical parameters on turbulent flow and heat transfer characteristics in outward helically corrugated tubes

Concerning a novel outward helically corrugated tube manufactured through hydraulic forming under 290 MPa, a numerical study was conducted to investigate the mechanism of turbulent flow dynamics and heat transfer enhancement based on the Reynolds stress model (RSM) using the FLUENT software. A validation of the Reynolds stress model for turbulent flow over a wavy surface was performed, and the results were then compared with the results from a large eddy simulation (LES) model and with experimental measurements. The helically corrugated tubes with different corrugation height-to-diameter ratios and pitch-to-diameter ratios are then evaluated to explore their influence on turbulent flow and heat transfer. It was found that the intensity of swirl flow was enhanced with an increase in the corrugation height, and it increased with a decrease in the corrugation pitch, the intensification of the swirl flow strengthens the heat transfer and resistance characteristics. The intensity of rotational flow was enhanced with an increase in the corrugation height, and increased with an increase in the corrugation pitch; the enhanced rotational flow causes an inhibition effect on heat transfer and resistance. Moreover, the maximum values of the local Nusselt number and the friction factor along the walls were observed at the reattachment point, and their minimum values appeared at the core of the swirl flow. It is therefore reasonable to keep the corrugation height-to-diameter ratios be less than 0.1, and the pitch-to-diameter ratios be less than 2 to ensure that the growth rate of the heat transfer is greater than the growth rate of the flow resistance.