Three-dimensional numerical simulations and experiments were carried out to study the heat transfer characteristics and the pressure drop of air flow in a circular tube with Edgefold-Twisted Tape （ETT） inserts and with classic Spiral-Twisted-Tape （STT） inserts of the same twist ratio. The RNG turbulence model for mildly swirling flows, the enhanced wall treatment for low Reynolds numbers, and the SIMPLE pressure-velocity method were adopted to simulate the flow and heat transfer characteristics. Within the range of Reynolds number from 2 500 to 9 500 and the twist ratio y from 5.4 to 11.4, the Nusselt number of the tube with ETT inserts is found to be 3.9% - 9.2% higher than that with STT inserts, and the friction factor of the tube with ETT inserts is 8.7% - 74% higher than that of STT inserts. The heat enhancement is due to higher tangential velocity and asymmetrical velocity profile with the increase and decrease of the periodic velocity within an edgefold length. It is found that main factors affecting the heat transfer of ETT inserts are the twist angle and the gap width between the tube and inserts. A larger twist angle leads to a higher tangential velocity, and larger Nusselt number and friction factor. The thermal-hydraulic performance slowly decreases as the twist angle increases. The gap width between tube and inserts has a significant influence on the heat transfer, while little influence on pressure drops. The thermal-hydraulic performance increases in average by 124% and 140% when the gap width reduces from 1.5 mm to 1.0 mm and 0.5 mm. The larger the gap width, the higher velocity through the gap will be, which would reduce the main flow velocity and tangential velocity. So a small gap is desirable. Comparing experimental and numerical results at variable air flow and tube wall temperature, the numerical results are found to be in a reasonable agreement with the experiment results, with difference of the Nusselt number in a range of 1.6% - 3.6%, and that of the friction factor in a range of 8
The characteristics of the longitudinal vortex induced by trapezoid-winglets in a circular tube are investigated by the Particle Image Velocimetry （PIV） Technique with flow Reynolds number in the range of 500-13 000. In the experimental test section, four trapezoid-winglets are fixed symmetrically on the tube wall in two different ways： up-flow and down-flow. The results show that a counter-rotating vortex pair is formed behind each winglet and they distribute as a symmetrical vortex array in the transverse section. Between the two vortexes in a vortex pair the fluid flows towards the wall in the up-flow winglet case and away from the wall in the down-flow winglet case, corresponding also to the regions of peak values of the velocity components normal to the mainstream. Both of the flow patterns enhance the velocity in the near wall region, leading to the intensification of the transverse mixing and the mass transfer in the tube. With Reynolds number increasing, the flow maintains the vortex pattern in the case of the up-flow winglets, indicating better persistence of the longitudinal vortex, while the vortexes in the case of the down-flow winglets are more scattered and tend to breaking into small eddies. The trapezoid winglet shows the preferable turbulent disturbance characteristics in the tube and the experimental results provide benchmark data for further CFD studies.
