Optimization of Sharp-Nose Tube Shapes for Enhanced Thermal–Hydraulic Performance in Heat-Exchanger Systems

This study numerically investigates the thermal–hydraulic performance of sharp-nose tube profiles for heat exchanger applications. Six geometries, including rounded and sharp-nose tubes with angles ranging from 20° to 45°, were analyzed at inlet velocities of 4 m/s and 12 m/s (Re = 7895–23,685). A thermal–hydraulic performance metric was used to evaluate the proposed designs against a drop-shaped tube. The results indicate that sharp-nose and double-nose profiles exhibit enhanced performance by 4–25% compared to the drop-shaped tube. The optimal configuration with a nose angle of θ=25° achieves the highest improvement in the thermal–hydraulic performance metric by 25.3% compared to the drop-shaped tube at Re = 7895. At lower Reynolds numbers, all sharp-nose configurations outperform the drop-shaped geometry, while performance converges at higher angles due to geometric similarity. The findings indicate that values calculated by employing the area-weighted average skin friction coefficient Cf‾ and the associated flow separation behavior play a central role in determining the thermal–hydraulic performance of the tube profiles. These findings highlight the potential of sharp-nose geometries for heat exchanger performance enhancement.