Prototyping Small Tank

What? Do a google search and I would bet there is some out there that is making a tank that size already that can be purchased off the shelve. Why reinvent the wheel. Also not sure what your doing but reducing heat this way unless you have lots of time is not a good way to approach.

A tank is the wrong shape to be used as a heat exchanger, as it has a low area per unit volume. Select a suitable heat exchanger instead. Heat exchangers have a high area per unit volume.

The purpose of a tank is to let the level go up and down. If that feature is not needed in the process, get rid of the tank altogether.

Just can't pick a tank size or heat exchanger. They have to be chosen on how much heat you need to get rid of from the oil. A tank will do the job if there is enough surface area, the flow rate is right and how it is ventilated. A heat exchanger for it's size will do much better. Forced air with a fan will improve performance on either.

Either way you need a tank. A welded steel one will do. Wall thickness on steel tank can be made thinner with same structural integrity as the thicker aluminum one. ThIS will make up most of the difference of the heat transfer rate of the aluminum tank. Cheaper too!

Gents, thanks. But let me put it clear. I need to make a funny shaped tank, preferably out of aluminum. I can make a 3D cad drawing. How to proceed to make a cheap prototype? If I could use off the shelf items, I wouldn't have started this tread, if I had room I would have chosen a heat exchanger, if it wasn't because weigh And heat transfer is an issue, I would have welded some thin steel plate together. :)

Engage the services of a sheet metal shop near you. They do this kind of thing every day. The tank will need to be welded together to prevent leaks, or failure.

1. 43 Defu Lane 9 6288 0555

   Salgar Enterprises Pte Ltd

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   Rolled Alloys Singapore

3. 28 Kelantan Road 6398 0020

   Teck Leong Metals

4. 4 Shenton Way 6226 4966

   Deetansa Singapore Pte Ltd

5. 21 Tuas South Street 1 6577 1818

   Global Metal (International ) Pte Ltd

Forget the Styrofoam, and go with this to get your shape. Cheap and easy.

http://cockeyed.com/lessons/papermache/papermache01.shtml

From there, find someone that knows how to pound metal into shape. You can use the paper mache figure to make a mold. Or you can do it yourself..........

http://www.doityourself.com/stry/shaping-metal-with-air-hammers-stepbystep

"I need to make a funny shaped tank, preferably out of aluminum."

"How to proceed to make a cheap prototype?"

I guess it's not about functionality!

I would start with something easy to get a hold of, like maybe a motorcycle gas tank, and go from there. But that's just me.

Note: I also wouldn't cut or weld until all gasoline was purged.

Hydraulic Reservoir Guide

I had a custom aluminum tank made for my motorcycle. The shop TIG welded it together. It was expensive, but it looks good and works well.

If you already have the parts that will surround the tank, could you spray them with a release agent, inject blown-in urethane foam, and then disassemble the surrounding items? This would leave a foam block of the desired shape.

Thanks. It's always nice with plenty replies, but so far nobody seams to understand what I'm looking for.

Kramarat: Thin slices of styrofoam of a well known thickness IS the way to make PRECISE and scaleable models of difficult shapes. After finishing glueing one can count layers, measure distance and angles much more precise than with papermache.

ozzb: it is ALSO about functionality, but I think COMPROMISE is the keyword.

lyn: like I said, I need a prototype, not off the shelf solutions. ;-)

welderman: I might go for a welded solution, but it's not going to work on the production line. Like you wrote, it's EXPENSIVE!

tornado: You are on to something there. Not a bad idea at all. But the tank is not to be in contact with the surroundings other than as little as possible so to hold it in place. I may even try to airflow my model on the outside in it's environment, so to adjust it for maximum cooling of the surface.

If, as you suggest, you are capable of welding steel... why not make the prototype from steel, then get a copy made from alu once the design is as you want it?

You're not paying attention.

Sheet metal shops make things one at a time. That means they can make one prototype, if that's what you want.

See #6

No experience but...

make your prototype in your foam. This means the shape can be mimiced in sheet material. If you go down the 'fill the area with expanding foam' you will , i am guessing, end up with a more amorphous shape not to be made from sheet, although molded aluminium is possible with dies, so that may be an option. But make it from sheet foam, keep making it till it's right, then take it to a catering equipment manufacturer, the kind that make tables, cabinets, sinks,etc. They tend to bend and weld ss and al, and see what they say. they may want drawings, they may say leave it with us, we'll work off that...

I can't see glue working in that environment, and if you could weld aluminium, you wouldn't be asking the question.

cnc

Catering equipment mfg. That is likely a place to go. Thanks! :-)

There is some ambiguity in your request, first you need to know what you are asking to be mass produced. For this you need a prototype, to test your idea. It may not even work. the prototype can test fit or function or both. Making the prototype will be more expensive than making one mass produced item, but less expensive than mass producing something that doesn't work, and won't be made the same way.

If you have a local foundry, perhaps making cast plaques and signs, and you took your model in, they would be able to give you a price.

It may be the vagueness, but I am intrigued...

I don't know why, but I started thinking about your project again.

All you're doing is dumping hot oil into a special tank and recirculating it back to whatever the piece of equipment is................

Here's a dumb question: Why do you need a tank?

Couldn't you accomplish the same thing with longer/larger diameter recirc piping, that could be configured however you wanted it?

Just take copper tubing and bend it into any shape you want. With more surface area, it will also displace the heat faster.

Well, I need a tank for 2 reasons. One is for room for expansion, the other is for settlement.

I am slowly beginning to accept the idea of a much simpler design reservoir with coils of tubing on the outside of it.

Sorry for mailing in the off the rack idea before I read the Tread.

For a prototype Copper is easier to work than aluminium as you can solder it as you go with no special tools or skill. It has thermal characteristics similar to aluminum and is much easier to work. If it starts to get hard anneal it with a torch. If it cracks seal it with solder.

If you consider build a model of the space see if it lends its self to being made in sections that can be removed in several pieces and reassembled out side the device. I might even use non harding modeling clay that can be cut away and put back on so the model can be taken out.

Step back and think about something else then have another look at this and see if it isn't a bit clearer to you.

Good luck

Gorddon

If only a small number of finished items will be made you might better spend your boss' money by finding an off the rack solution. A 1.5 liter aluminum pressure cooker would hold about 3 liters or cutting the bottom off one two liter aluminum water bottle and the top off another and welding the then together would be an inexpensive solution if you can't find a ready made 3 liter tank.

If you really need cooling three 1 liter water bottles feeding one to the next will give booth good cooling and time for thing to settle in the first two tanks.

Good Luck

GC

Does anybody have experience with ceramic or plaster dies for casting alu or magnesium? I'm doing my best to read up on the topic, as I can understand that's the way foundries starts prototyping. I wouldn't be too worried if it takes a bit of time, as long as its my own time.

I feel that you may be jumping at least one step too far with this suggestion. As you are still on "proof of concept" - at least with this component - the expansion/heat control you require is still in question. Go with one of the suggestions to produce the prototype from a sheet material: steel, for cheapest option, ease of welding; copper, dearer material, but easier to work and closer to performance of alu. Once you have confirmed the design and shape(s), then look further into casting, or whatever means... It may be that a casting with cooling fins is most appropriate for your needs but these come at a cost you will unlikely want or a first prototype.

Well, lets just pretend that I have been there, done that! Next step please. :-)

There is no way you can cast aluminum in your house or workshop.

Check the melting temperature of aluminum.

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for a one off it's a sand mold made from a 3d model + 7% for contraction, i think

As suggested in a previous post, copper is an easy and cost effective material to work with. It is easy to form, has better conductivity than aluminum, and joints can be soft or silver soldered. Before you ignore this suggestion, it would be helpful to know what you don't like about it.