Study of Flow and Heat Transfer in High Pressure Die Casting Cooling Channel

Arunkumar, K. A.; Bakshi, Shamit; Phanikumar, Gandham; Rao, T. V. L. Narasimha

doi:10.1007/s11663-023-02785-6

Cited by 3 publications

(3 citation statements)

References 14 publications

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“…If a manufacturer of jet coolers had a specific requirement for the spatial distribution of HTC, e.g., to maximize it or to make it more uniform, the IHCP solver could be used in the design of these products. As a semi-experimental tool, it is suitable for the verification of fluid flow simulations [38], commonly used for the same purpose as the jet cooler design.…”

Section: Discussionmentioning

confidence: 99%

Experimental and Numerical Investigations into Heat Transfer Using a Jet Cooler in High-Pressure Die Casting

Bohacek,

Mraz,

Krutis

et al. 2023

JMMP

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During high-pressure die casting, a significant amount of heat is dissipated via the liquid-cooled channels in the die. The jet cooler, also known as the die insert or bubbler, is one of the most commonly used cooling methods. Nowadays, foundries casting engineered products rely on numerical simulations using commercial software to determine cooling efficiency, which requires precise input data. However, the literature lacks sufficient investigations to describe the spatial distribution of the heat transfer coefficient in the jet cooler. In this study, we propose a solver using the open-source CFD package OpenFOAM and free library for nonlinear optimization NLopt for the inverse heat conduction problem that returns the desired distribution of the heat transfer coefficient. The experimental temperature measurements using multiple thermocouples are considered the input data. The robustness, efficiency, and accuracy of the model are rigorously tested and confirmed. Additionally, temperature measurements of the real jet cooler are presented.

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Section: Discussionmentioning

confidence: 99%

Experimental and Numerical Investigations into Heat Transfer Using a Jet Cooler in High-Pressure Die Casting

Bohacek,

Mraz,

Krutis

et al. 2023

JMMP

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“…Recently, some commercial software in the market was used to simulate the heat conduction of filling and solidification during the die-casting process successfully [130]. Assisted by MAGMASOFT ® and ANSYS Fluent ® , K. Arunkumar et al [131] developed a coupled simulation strategy to determine accurate heat transfer coefficients of the die-cooling Recently, some commercial software in the market was used to simulate the heat conduction of filling and solidification during the die-casting process successfully [130]. Assisted by MAGMASOFT ® and ANSYS Fluent ® , K. Arunkumar et al [131] developed a coupled simulation strategy to determine accurate heat transfer coefficients of the diecooling channel and optimized the key parameters in the solidification of the die casting.…”

Section: Rheological High-pressure Die Castingmentioning

confidence: 99%

“…Assisted by MAGMASOFT ® and ANSYS Fluent ® , K. Arunkumar et al [131] developed a coupled simulation strategy to determine accurate heat transfer coefficients of the die-cooling Recently, some commercial software in the market was used to simulate the heat conduction of filling and solidification during the die-casting process successfully [130]. Assisted by MAGMASOFT ® and ANSYS Fluent ® , K. Arunkumar et al [131] developed a coupled simulation strategy to determine accurate heat transfer coefficients of the diecooling channel and optimized the key parameters in the solidification of the die casting. Furthermore, ANSYS Fluent ® was also used to obtain the interface heat transfer coefficients during the die-casting process and clarified the influence factors (injection pressure, injection second phase velocity, casting temperature, vacuum, etc.)…”

Section: Rheological High-pressure Die Castingmentioning

confidence: 99%

Research Progress on Thermal Conductivity of High-Pressure Die-Cast Aluminum Alloys

Liu,

Xiong

2024

Metals

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High-pressure die casting (HPDC) has been extensively used to manufacture aluminum alloy heat dissipation components in the fields of vehicles, electronics, and communication. With the increasing demand for HPDC heat dissipation components, the thermal conductivity of die-cast aluminum alloys is paid more attention. In this paper, a comprehensive review of the research progress on the thermal conductivity of HPDC aluminum alloys is provided. First of all, we introduce the general heat transport mechanism in aluminum alloys, including electrical transport and phonon transport. Secondly, we summarize several common die-cast aluminum alloy systems utilized for heat dissipation components, such as an Al–Si alloy system and silicon-free aluminum alloy systems, along with the corresponding composition optimizations for these alloy systems. Thirdly, the effect of processing parameters, which are significant for the HPDC process, on the thermal conductivity of HPDC aluminum alloys is discussed. Moreover, some heat treatment strategies for enhancing the thermal conductivity of die-cast aluminum alloys are briefly discussed. Apart from experimental findings, a range of theoretical models used to calculate the thermal conductivity of die-cast aluminum alloys are also summarized. This review aims to guide the development of new high-thermal-conductivity die-cast aluminum alloys.

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Determination of transient heat transfer by cooling channel in high-pressure die casting using inverse method

Bohacek,

Mraz,

Hvozda

et al. 2024

J. Phys.: Conf. Ser.

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Complex shapes of aluminum castings are typically manufactured during the short cycle process known as the high-pressure die casting (HPDC). High productivity is ensured by introducing die cooling through a system of channels, die inserts or jet coolers. Die cooling can also effectively help in reducing internal porosity in cast components. Accurate simulations based on sophisticated numerical models require accurate input data such as material properties, initial and boundary conditions. Although the heat is dominantly dissipated through die cooling, indicating the importance of knowing precise thermal boundary conditions, open literature lacks a detailed information about the spatial distribution of heat transfer coefficient. This study presents an inverse method to determine accurate heat transfer coefficients of a die insert based on temperature measurements in multiple points by 0.5 mm K-type thermocouples and a subsequent solution of the two-dimensional inverse heat conduction problem. The solver was built in the open-source CFD code OpenFOAM and the free library for nonlinear optimization NLopt. The results are presented for the commonly used 10 mm die insert with a hemispherical tip and coolant flow rates ranging from 100 l/h to 200 l/h. Heat transfer coefficients reach values well above 50 kW/m2K in the hemispherical tip, which is followed by a secondary peak and then a gradual drop to values around 1 kW/m2K further downstream.

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Study of Flow and Heat Transfer in High Pressure Die Casting Cooling Channel

Cited by 3 publications

References 14 publications

Experimental and Numerical Investigations into Heat Transfer Using a Jet Cooler in High-Pressure Die Casting

Experimental and Numerical Investigations into Heat Transfer Using a Jet Cooler in High-Pressure Die Casting

Research Progress on Thermal Conductivity of High-Pressure Die-Cast Aluminum Alloys

Determination of transient heat transfer by cooling channel in high-pressure die casting using inverse method

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