Determination of the metal/die interfacial heat transfer coefficient and its application in evaluating the pressure distribution inside the casting during the high pressure die casting process

Guo, Zhao‐Xia; Xiong, Shoumei; Liu, B. C.; Li, M.; Allison, J.

doi:10.1179/136404609x368109

Cited by 8 publications

(5 citation statements)

References 2 publications

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“…Some studies have shown that the applied pressure will affect the interface heat transfer coefficient between the metal melt and the metal die [ 47 , 48 , 49 , 50 , 51 ]. It is generally believed that the liquid contacts the metal surface more closely after the melt is pressurized.…”

Section: Methodsmentioning

confidence: 99%

Numerical Simulation and Experimental Study on Compound Casting of Layered Aluminum Matrix Composite Brake Drum

2021

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The requirements of high-strength, wear-resistance and lightweight of brake drums have been continually increasing in recent years and any specific aluminum alloy or particle-reinforced aluminum matrix composites may not satisfy all the demands. Combining dissimilar materials to play their respective advantages is a solution to this problem. In this study, a compound casting method was used to combine solid SiCp/A357 composite and a liquid 7050 aluminum alloy to prepare an aluminum matrix composite with a layered structure. The ProCAST numerical simulation software was used to predict the heat transfer in compound casting process and guide the preheating temperature of the wear-resistant ring in the experiment. An Optical Microscope (OM) and Scanning Electron Microscope (SEM) were used to observe microstructures around the solid–liquid bonding interface, the element distribution and phase component of which were analyzed by Energy Dispersive Spectroscopy (EDS) and mechanical properties were evaluated by microhardness and shear tests. The results showed that the interface of the layered aluminum matrix composite prepared by this method achieved complete metallurgical bonding and a transition zone formed on the solid surface. After T6 heat treatment, the average shear strength of the interface increased from 19.8 MPa to 33.8 MPa.

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Section: Methodsmentioning

confidence: 99%

Numerical Simulation and Experimental Study on Compound Casting of Layered Aluminum Matrix Composite Brake Drum

2021

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“…Determining the heat flux from the alloy to the sand often involves experimental measurements or numerical simulations [11], as it depends on various factors such as contact pressure, surface finishing, sand grain dimensions, coating thickness, and deformation of the casting, which can be difficult to model analytically. In GSC simulations, this heat flux is modelled as an overall Heat Transfer Coefficient (HTC), which is the proportionality constant between heat flux and temperature difference between the contacting surfaces per unit area [12,13]. The HTC between casting and mould surfaces is not precisely known, and the simulations rely on typical HTC values available in the software database.…”

Section: Introductionmentioning

confidence: 99%

Identification of Heat Transfer Parameters for Gravity Sand Casting Simulations

Vergnano,

Facondini,

Morselli

et al. 2024

Machines

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Gravity sand casting simulations require accurate modelling of heat transfer phenomena to reliably evaluate the expected quality of the produced parts. Average model parameters can be easily retrieved from a validated database. However, these parameters are highly dependent on the specific sand used and the actual forming process in the foundry. Furthermore, the heat transfer from the solidifying alloy to the mould surfaces is not precisely known, so simulation models usually use typical values for overall heat transfer coefficients. Most research works investigate individual parameters, whereas heat transfer phenomena largely arise from their interaction together. Therefore, the present work describes a combined experimental and computational method based on genetic algorithm techniques for determining the most important parameters for heat transfer in a sand mould. The experiments examine both virgin and reused sand, as these are alternatively used in the foundry for mould forming. The density, thermal conductivity, and specific heat capacity of the different sands are identified, along with heat transfer coefficients. The counterproof simulations demonstrate that the standard parameters are quite reliable for virgin sand. However, in the case of reused sand, the identified parameters lead to more reliable results.

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“…8 Inverse problems in heat transfer involve thermal parameter and boundary condition estimation using the measured thermal history, noting that when thermal properties are a function of temperature, the problem becomes non-linear. 9 Various numerical techniques involving heuristics, gradient-based or other classical optimisation methods have been employed for the solution of inverse problems in casting, e.g. 'control volume technique', 10 'Maximum a Posteriori (MAP)' algorithm, 11 etc.…”

Section: Introductionmentioning

confidence: 99%

Determination of local heat transfer coefficients in precision castings by genetic optimisation aided by numerical simulation

Vasileiou

Vosniakos

Pantelis

2014

Proceedings of the Institution of Mechanical Engineers, Part C:

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The heat transfer coefficient between casting and mould is the most crucial parameter in predicting the evolution of solidification and the resulting properties of the part. In numerical simulations setting, heat transfer coefficient value is considered an ill-posed, inverse problem that requires experimental data, whose solution, if at all possible to reach, is often numerically correct but physically meaningless. In this paper, it is proposed to use a Genetic Algorithm which stochastically explores alternative heat transfer coefficient values. These are evaluated by running a numerical simulation and comparing the resulting cooling curves at a number of nodes of interest to their experimentally measured counterparts until a close enough match is achieved. The combinatorial complexity of determining different heat transfer coefficients corresponding to different regions of complex castings, which are selected due to their differing casting moduli, is possible to tackle in this way with reasonable computational resources. Furthermore, different well-established forms of heat transfer coefficient function can be tried, notably heat transfer coefficient as a function of time (either stepwise or exponential) and as a stepwise function of temperature. Integer encoding in the Genetic Algorithm and a database of accumulating simulation results are features that were developed in order to reduce computational load. The approach is successfully demonstrated on a brass part produced by investment casting, exhibiting three sections of different casting moduli.

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Determination of the metal/die interfacial heat transfer coefficient and its application in evaluating the pressure distribution inside the casting during the high pressure die casting process

Cited by 8 publications

References 2 publications

Numerical Simulation and Experimental Study on Compound Casting of Layered Aluminum Matrix Composite Brake Drum

Numerical Simulation and Experimental Study on Compound Casting of Layered Aluminum Matrix Composite Brake Drum

Identification of Heat Transfer Parameters for Gravity Sand Casting Simulations

Determination of local heat transfer coefficients in precision castings by genetic optimisation aided by numerical simulation

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