Novel cooling channel shapes in pressure die casting

L. D. Clark, K. Davey, S. Hinduja

    Research output: Contribution to journalArticlepeer-review


    The pressure die casting involves die designs incorporating cooling channels positioned to facilitate the controlled extraction of energy from a solidifying casting. It is now known that subcooled nucleate boiling can occur in cooling channels and this paper is concerned with novel cooling channel shapes that are optimized to promote and enhance this boiling and thus reduce casting times. Shape sensitivity analysis is applied to a boundary element model using the material derivative adjoint variable technique. Mesh node positions on the cooling channels are used as the design parameters. The sensitivities are used in a conjugate gradient non-linear optimization routine. It is shown that with this approach cooling channels can be designed to maximize boiling heat transfer whilst at the same time allow some degree of control of spatial temperature variation over the die cavity surface. Simulation and experimental results are presented for a traditional die and an optimized die. A 60 per cent reduction in cycle time is achieved with the optimized die. Copyright © 2001 John Wiley & Sons, Ltd.
    Original languageEnglish
    Pages (from-to)2411-2440
    Number of pages29
    JournalInternational Journal for Numerical Methods in Engineering
    Issue number10
    Publication statusPublished - 10 Apr 2001


    • Boiling models
    • Material derivative-adjoint variable technique
    • Pressure diecasting
    • Shape optimization


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