The modeling of the pressure die casting process generally requires the specification of heat transfer coefficients at the surfaces of the die. The coefficients at the cavity-casting interface and at the cooling channel surfaces are of particular importance. In order to provide estimates for these heat transfer coefficients, the behavior of a specifically designed zinc alloy casting is investigated using a three dimensional thermal model whose predictions are supported by experimentally obtained results. The numerical model uses the boundary element method for the dies, as surface temperatures are of particular importance, and the finite element method for the casting, where the nonlinear material behavior makes this technique suitable. The experimental data comprises of thermocouple measurements of both die, casting, and coolant temperatures for three sets of operating conditions. These measurements are complemented by qualitative data of casting defects caused by incomplete solidification and thermal imaging temperature measurements. An experimental technique for obtaining average heat transfer coefficients for the casting–die interface is presented. Although the technique circumvents the need to place thermocouples in the casting and provides average heat transfer coefficients of sufficient accuracy for modeling purposes, it is not sufficiently responsive to provide accurate transient information. The presence of coolant boiling is detected by its effect on the rates of heat extraction. Heat transfer coefficients are determined for the cooling channels using a boiling model. Comparison between predicted and experimental rates of heat transfer to the coolant support the need for a boiling model. Good agreement is obtained between experimental and numerical predictions. [S1087-1357(00)00601-8]
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February 2000
Technical Papers
An Experimental and Numerical Investigation into the Thermal Behavior of the Pressure Die Casting Process
S. Bounds,
S. Bounds
Department of Mechanical Engineering, UMIST, Manchester M60 1QD, United Kingdom
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K. Davey,
K. Davey
Department of Mechanical Engineering, UMIST, Manchester M60 1QD, United Kingdom
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S. Hinduja
S. Hinduja
Department of Mechanical Engineering, UMIST, Manchester M60 1QD, United Kingdom
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S. Bounds
Department of Mechanical Engineering, UMIST, Manchester M60 1QD, United Kingdom
K. Davey
Department of Mechanical Engineering, UMIST, Manchester M60 1QD, United Kingdom
S. Hinduja
Department of Mechanical Engineering, UMIST, Manchester M60 1QD, United Kingdom
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received Oct. 1997; revised July 1999. Associate Technical Editor: K. Stelson.
J. Manuf. Sci. Eng. Feb 2000, 122(1): 90-99 (10 pages)
Published Online: July 1, 1999
Article history
Received:
October 1, 1997
Revised:
July 1, 1999
Citation
Bounds , S., Davey , K., and Hinduja , S. (July 1, 1999). "An Experimental and Numerical Investigation into the Thermal Behavior of the Pressure Die Casting Process ." ASME. J. Manuf. Sci. Eng. February 2000; 122(1): 90–99. https://doi.org/10.1115/1.538890
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