This study investigates the Nusselt number (Nu), friction factor (f), and thermohydraulic performance (η) in a heat exchanger tube (HET) equipped with hyperbolic cut twisted tapes (HCTTs). This research investigates the effects of hyperbolic-cut and cut-width ratio configurations under turbulent flow conditions. Experiments were conducted to assess thermohydraulic performance by varying hyperbolic-cut ratios ( \(b/c\) = 0.3, 0.6, 0.9, and 1.2) and cut-width ratios ( \(c/w\) = 0.56, 0.67, 0.78, and 0.89) across a Reynolds number (Re) range of 10,000 to 22,000, under conditions of constant heat flux. The cuts in the twisted tape (TT) induce swirling flow, enhancing fluid mixing between the near-wall and core regions of the HET. The Internet of Things (IoT) approach was employed to monitor input and output variables, measure flow rates, reduce errors, and enhance automation, resulting in more accurate outcomes by minimizing manual involvement. The results reveal significant improvements: Nu increased by 2.11–22.29%, f rose by 31.28–61.08%, and η improved by 0.33–11.63% compared to plain TT. This comprehensive analysis showed superior performance across all Re values relative to previous studies. Using regression analysis, correlations for Nu and f were established based on the variables Re, Pr, \(b/c\) , and \(c/w\) , achieving correlation errors of ± 12% for Nu and ± 9% for f. Finally, this experimental investigation of flow and thermal behaviors was conducted to gain deeper insights into underlying heat transfer mechanisms.
