Determination of heat transfer coefficients using a 1-d flow model applied to irregular shaped cooling channels in pressure diecasting

A mesh partitioning strategy is presented which facilitates the application of boundary conditions to irregular shaped cooling channels in the pressure diecasting process. The strategy is used to partition a boundary element mesh, but can also be applied to the surface of a cooling channel bounded by a finite element mesh. The partitioning of the mesh into a series of element packs enables a one-dimensional flow model to be applied to the coolant. The flow model is used in conjunction with a steady-state thermal model which initially assumes that no boiling is taking place on the die/coolant interface. Values of bulk temperature, pressure, and velocity in the coolant are thus ascertained. This information, together with die temperatures, is then used in empirical relationships which model the various heat transfer mechanisms, including nucleate and transitional film boiling, between die and coolant. Effective heat transfer coefficients are calculated and applied at the die/coolant interface. The steady-state thermal code and the empirical boiling model are then used iteratively until stable values for the effective heat transfer coefficients are obtained. The models are tested by casting a small thin component using a die with conventional cooling channels and also using a novel die with irregular shaped cooling channels running on a hot chamber proprietary die casting machine. Simulation results are shown and experimental results using the hot chamber pressure die casting machine are reported.