Novel cooling channel shapes in pressure die casting

Clark, L D; Davey, Keith; Hinduja, S.

doi:10.1002/nme.126

Cited by 11 publications

(4 citation statements)

References 27 publications

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“…The heat transfer between casting and coolant was modeled and measured in [44]. The effect of boiling in cooling channels was analyzed in [45] to propose new criteria for the optimization of channel layout. The thermal distortion of the die during the die casting cycle was simulated in [46] to optimize some design variables related to cooling channels.…”

Section: Introductionmentioning

confidence: 99%

SLM tooling for die casting with conformal cooling channels

Armillotta

Baraggi

Fasoli³

2013

Int J Adv Manuf Technol

151

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The paper reports an experimental study of die-casting dies with conformal cooling fabricated by direct-metal additive techniques. The main objective is to compare the benefits and limitations of the application to what has been widely discussed in literature in the context of plastics injection molding.Selective laser melting was used to fabricate an impression block with conformal cooling channels, designed according to part geometry with the aid of process simulation. The tool was used in the manufacture of sample batches of zinc alloy castings, after being fitted on an existing die in place of a machined impression block with conventional straight-line cooling channels. Different combinations of process parameters were tested to exploit the improved performance of the cooling system. Test results show that conformal cooling improves the surface finish of castings due to a reduced need of spray cooling, which is allowed by a higher and more uniform cooling rate. Secondary benefits include reduction of cycle time and shrinkage porosity. KeywordsSelective laser melting; rapid tooling; die casting; conformal cooling; spray cooling; surface finish. 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 1 Title pageClick here to download Manuscript: titlepage.doc Click here to view linked References 1 2 3 4 5 6 7 8 SLM tooling for die casting with conformal cooling channels AbstractThe paper reports an experimental study of die-casting dies with conformal cooling fabricated by direct-metal additive techniques. The main objective is to compare the benefits and limitations of the application to what has been widely discussed in literature in the context of plastics injection molding.Selective laser melting was used to fabricate an impression block with conformal cooling channels, designed according to part geometry with the aid of process simulation. The tool was used in the manufacture of sample batches of zinc alloy castings, after being fitted on an existing die in place of a machined impression block with conventional straight-line cooling channels. Different combinations of process parameters were tested to exploit the improved performance of the cooling system. Test results show that conformal cooling improves the surface finish of castings due to a reduced need of spray cooling, which is allowed by a higher and more uniform cooling rate. Secondary benefits include reduction of cycle time and shrinkage porosity.

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Section: Introductionmentioning

confidence: 99%

SLM tooling for die casting with conformal cooling channels

Armillotta

Baraggi

Fasoli³

2013

Int J Adv Manuf Technol

151

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“…As mentioned in the introduction a particular problem of the type under discussion arises in pressure die casting [21,22]. Illustrated in Figure 2 is the problem under consideration.…”

Section: A Particular Problemmentioning

confidence: 99%

Sensitivity and optimization for shape and non‐linear boundary conditions in thermal boundary elements

Davey¹,

Clark²

2002

Numerical Meth Engineering

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SUMMARYThis paper is concerned with the minimization of functionals of the form (b) where variation of the vector b modiÿes the shape of the domain on which the potential problem,The vector h is dependent on non-linear boundary conditions that are deÿned on the boundary . The method proposed is founded on the material derivative adjoint variable method traditionally used for shape optimization. Attention is restricted to problems where the shape of is described by a boundary element mesh, where nodal co-ordinates are used in the deÿnition of b.Propositions are presented to show how design sensitivities for the modiÿed functional (b) can be derived more readily with knowledge of the form of the adjoint function determined via non-shape variations. The methods developed in the paper are applied to a problem in pressure die casting, where the objective is the determination of cooling channel shapes for optimum cooling. The results of the method are shown to be highly convergent.

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“…Figure 4 shows a procedure, henceforth referred to as method I, which has previously been used to optimize cooling channel con®gurations [19]. The method begins with a boundary element method (BEM) thermal analysis, with the assumption that forced convection is the sole heat transfer mechanism on the cooling channel surfaces.…”

Section: Heat Transfer On a Boundary Element Meshmentioning

confidence: 99%

Optimization for boiling heat transfer determination and enhancement in pressure die casting

Davey

Hinduja

Clark

2002

Proceedings of the Institution of Mechanical Engineers, Part B:

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Boiling in cooling channels has recently been demonstrated to be an effective mechanism for heat extraction in pressure die casting. Boiling heat transfer can be enhanced by cooling channel shape optimization. The occurrence of boiling presents a non-linear thermal problem which, when combined with shape optimization, necessitates the solving of non-linear equations for each channel configuration. In this paper a methodology is presented that involves the use of optimization for the combined determination of channel shapes and heat transfer coefficients. It is shown in the paper how this approach results in the accurate determination of boiling heat transfer coefficients on the final optimized cooling channel configuration. The non-linear thermal problem is calculated at very little computational cost over that required for a comparable linear problem. Focus in the paper is on the application of the methodology to the pressure die casting process. The approach adopted is founded on a design sensitivity analysis using the material derivative adjoint variable method. The thermal model for the pressure die casting process is founded on the boundary element method and the optimization is performed using a conjugate gradient scheme. Geometrical constraints are enforced using buffer elements superimposed on to the boundary element mesh. Numerical and experimental trials are performed to demonstrate the potential of the new optimization methodology.

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Novel cooling channel shapes in pressure die casting

Cited by 11 publications

References 27 publications

SLM tooling for die casting with conformal cooling channels

SLM tooling for die casting with conformal cooling channels

Sensitivity and optimization for shape and non‐linear boundary conditions in thermal boundary elements

Optimization for boiling heat transfer determination and enhancement in pressure die casting

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