DEVELOPMENT OF AN INVERSE HEAT TRANSFER MODEL BETWEEN MELT AND SHOT SLEEVE AND ITS APPLICATION IN HIGH PRESSURE DIE CASTING PROCESS

doi:10.11900/0412.1961.2014.00604

Acta Metall Sin

2015, Vol. 51

Issue (6): 745-752 DOI: 10.11900/0412.1961.2014.00604

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DEVELOPMENT OF AN INVERSE HEAT TRANSFER MODEL BETWEEN MELT AND SHOT SLEEVE AND ITS APPLICATION IN HIGH PRESSURE DIE CASTING PROCESS

Yongyou CAO,Shoumei XIONG,Zhipeng GUO(

)

School of Materials Science and Engineering, Tsinghua University, Beijing 100084

Cite this article:

Yongyou CAO, Shoumei XIONG, Zhipeng GUO. DEVELOPMENT OF AN INVERSE HEAT TRANSFER MODEL BETWEEN MELT AND SHOT SLEEVE AND ITS APPLICATION IN HIGH PRESSURE DIE CASTING PROCESS. Acta Metall Sin, 2015, 51(6): 745-752.

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Abstract

A 2D inverse heat transfer model between molten metal and shot sleeve was based on the nonlinear estimation method. Die casting experiments under both non-shot and shot conditions (via the plunger) were performed using an Al-9%Si-3%Cu alloy. Based on the temperature measurements from thermocouples embedded inside the shot sleeve, the temperature distribution of molten metal and interfacial heat transfer coefficient (IHTC) were successfully determined. Results show that the heat transfer behavior of non-shot condition was different from that in the shot condition, but the IHTC in the middle zone of shot sleeve decreased along the plunger moving direction. Besides, the surface temperature of shot sleeve was higher in both pouring zone and end zone while lower in the middle zone. In accordance to the movement of the plunger, the IHTC profile in the end zone exhibited double peaks.

Key words: high pressure die casting shot sleeve interfacial heat transfer coefficient inverse method

Fund: Supported by National Natural Science Foundation of China (Nos.51275269 and 51205229) and National Science and Technology Major Project (No.2012ZX04012011)

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https://www.ams.org.cn/EN/10.11900/0412.1961.2014.00604 OR https://www.ams.org.cn/EN/Y2015/V51/I6/745

Fig.1 Configuration and boundary conditions of the shot sleeve (z, x—coordinate axis of the shot sleeve; q, q_r—heat flux density; x_A , x_B, x_C—sensor location (1, 3 and 6 mm); Δx—grid size)

(a) cross section (b) longitude section (c) heat transfer model

Fig.2 Schematic of temperature measurement design for the shot sleeve (unit: mm)

Table 1 Thermal properties of related materials

Fig.3 Sequence temperatures measured at 1 mm from the interface at S2, S5 and S10 during 8 cycles under the non-shot condition

Fig.4 Solidified metal log in the 8th cycle under the non-shot condition

Fig.5 Typical calculated results of shot sleeve at S5 position during the 8th cycle under the non-shot condition (T_mu, T_mi—temperatures of the metal upper surface and interface; T_si—shot sleeve surface temperature; T₁, T₃, T₆—measured temperatures at 1, 3 and 6 mm from interface in the shot sleeve; h—interfacial heat transfer coefficient; q—interfacial heat flux density; T_3c—calculated temperature at 3 mm from interface in the shot sleeve)

Fig.6 Thermal field of metal log at 18 s in the shot sleeve for 8 cycles under the non-shot condition (z, R—coordinate axises of the shot sleeve)

Fig.7 Calculated interfacial heat transfer coefficients (IHTCs) at different locations during the 8th cycle under the non-shot condition

Fig.8 Calculated 2D temperature distribution of the metal inside the shot sleeve during slow filling (a), fast filling (b) and end of filling (c)

Fig.9 Calculated IHTCs at the shot sleeve surface during the 7th cycle during HPDC process

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