Design and Analysis of a Heat Exchanger Prototype using the Design for Manufacturing and Assembly (DFMA) Method with ANSYS Thermal Simulation

Naufal Rafif Juliardi; Krisna Satiya Putra; Moch Daffa’ Dzakwan; Nandana Janitra Prasojo; Singgih Dwi Prasetyo

Authors

Naufal Rafif Juliardi Power Plant Engineering Technology, Faculty of Vocational Studies, State University of Malang, Malang 65145, Indonesia
Krisna Satiya Putra Power Plant Engineering Technology, Faculty of Vocational Studies, State University of Malang, Malang 65145, Indonesia
Moch Daffa’ Dzakwan Power Plant Engineering Technology, Faculty of Vocational Studies, State University of Malang, Malang 65145, Indonesia
Nandana Janitra Prasojo Power Plant Engineering Technology, Faculty of Vocational Studies, State University of Malang, Malang 65145, Indonesia
Singgih Dwi Prasetyo Power Plant Engineering Technology, Faculty of Vocational Studies, State University of Malang, Malang 65145, Indonesia

Keywords:

Heat exchanger, DFMA, ANSYS

Abstract

The design of small-scale heat exchangers requires an approach that considers not only thermal performance but also manufacturability and low production costs. Common challenges include component complexity and high manufacturing costs in conventional designs. This study aims to design and analyze a functional, easily manufacturable, and economical heat exchanger prototype using the Design for Manufacturing and Assembly (DFMA) approach. The methods employed include conceptual design, assembly feasibility analysis, and heat transfer simulation using ANSYS to evaluate temperature distribution and heat transfer efficiency. The prototype consists of a PVC pipe as the casing, a spiral copper coil as the heat transfer medium, a water pump as a closed-loop circulation system, and a pan as the reservoir. The design results show that the prototype consists of 12 components with an estimated production cost of Rp319,000 and an assembly time of approximately 1–2 weeks using simple tools.