Compare Between the Results of the Casting Simulation and the Results of Experimental Production with Calculating the Interface Heat Transfer Coefficient of the Casting-Mold

Abstract

Sanitary tapware that can drain hot and cold water from the plumbing systems in the desired proportions by mixing are called faucet. The production of faucets used today is conducted by using a low-pressure casting method. The raw material of the body, which is the main part of faucets, is generally brass alloy (CuZn39Pb1Al-C). The material of faucet molds produced using the casting method is the copper-beryllium alloy (CuCoNiBe). In this research, K type thermocouples were placed into the mold in such a way that there was a distance of 3 mm to the casting surface, and temperature changes during the production were achieved by the measurement and recording device. 1283,1263,1243,1223,1203,1183,1163 K values of casting temperatures that were identified as critical in Ansys Fluent program and interfacial heat transfer coefficient of the combinations created by casting temperatures of 413,473,533,593,653 K were calculated numerically. Casting simulation was created in Magma program by using calculated IHTC values, and they were analysed by making a comparison between experimental and simulation temperature curves. The match of the defects was controlled by comparing the defect results of simulation in which convergence within temperature curves were provided and the defects of scrap parts in experimental production.

Keywords

• Casting Defects,Casting Simulation,CFD,Copper-Beryllium Alloy,Interface Heat Transfer Coefficient (IHTC),Low Pressure Die Casting,Porosity Analysis

Supporting Institution

TÜBİTAK - TEYDEB 1501

Project Number

3170587

Thanks

Our research was supported by Technology and Innovation Funding Programs Directorate (TEYDEB) of The Scientific and Technological Research Council of Turkey (TUBITAK) within 1501 coded Industrial R&D Projects Grant Programme with the project number of 3170587. In addition, we owe a debt of gratitude to E.C.A. Valfsel Armatur Sanayi A.S., one of the biggest faucet manufacturer companies of our country, and Gökhan Topgüner as R&D manager and Sinan Aydın as mold designer and Mehmet Tunç as mold designer.

References

1. [1]. Michels, HT. 2009. Copper-Base Alloys, Casting Source Directory, Metal Casting Design & Purchasing; 31-34.
2. [2]. Susac, F, Ohura, K, Banu, A, Makinouchi, M. 2015. Determination of heat transfer coefficient and air gap in aluminum casting by numerical and experimental approaches. Manufacturing Process Simulation Team, VCAD System Research; 69-70.
3. [3]. Arunkumar, S, Sreenivas-Rao, KV, Prasanna-Kumar, TS. 2008. Spatial variation of heat flux at the metal-mold interface due to mold filling effects in gravity die-casting. International Journal of Heat and Mass Transfer; 51: 2676-2685.
4. [4]. Taha, MA, El-Mahallawy, NA, El-Mestekawi, MT, Hassan, AA. 2013. Estimation of air gap and heat transfer coefficient at different faces of al and Al–Si castings solidifying in permanent mould. Materials Science and Technology; 17(9): 1093-1101.
5. [5]. Pathak, N, Kumar, A, Yadav, A, Pradip, D. 2009. Effects of mould filling on evolution of the solid-liquid interface during solidification. Applied Thermal Engineering; 29: 3669-3678.
6. [6]. Lan, P, Li, L, Tie, Z, Tang, H, Zhan, J. 2019. Combined study on mold taper and corner radius in bloom continuous casting by fem simulation and trial experiment. Metals and Materials International; 25(6): 1603-1615.
7. [7]. Rafique, MMA, Iqbal, J. 2009. Modeling and simulation of the phenomena during investment casting. International Journal of Heat and Mass Transfer; 52: 2132-2139.
8. [8]. Xuan-xuan, Y, Ling, C, Yi-jie, H. 2012. Numerical simulation of casting filling process based on Fluent. Energy Procedia; 17: 1864-1871.

9. [9]. Pehlke, RD, Berry, JT. 2005. Investigation of heat transfer at the mold/metal interface in permanent mold casting of light alloys. Technical Report, The University of Michigan; 02ID14236: 1-85.
10. [10]. Sun, J, Le, Q, Fu, L, Bai, J, Tretter, J, Herbold, K, Huo, H. 2019. Gas entrainment behavior of aluminum alloy engine crankcases during the low pressure die casting process. Journal of Materials Processing Technology; 266: 274-282.
11. [11]. Li, YY, Tsai, DC. Hwang W.S., “Numerical simulation of the solidification microstructure of a 17-4PH stainless steel investment casting and its experimental verification. 2008. Modelling and Simulation in Materials Science and Engineering; 16(4): 1-15.
12. [12]. Park, J-J. 2014. Finite-element analysis of a vertical twin-roll casting. 2014. Metals and Materials International; 20(2): 317-322.
13. [13]. Jiang, W, Fan, Z, Liu, D, Liao, D, Dong, X, Zong, X. 2013. Correlation of microstructure with mechanical properties and fracture behavior of A356-T6 aluminum alloy fabricated by expendable pattern shell casting with vacuum and low-pressure, gravity casting and lost foam casting. Materials Science and Engineering A; 560: 396–403.
14. [14]. Long, A, Thornhill, D, Armstrong, C, Watson, D. 2011. Determination of the heat transfer coefficient at the metal-die interface for high pressure die cast AlSi9Cu3Fe. Applied Thermal Engineering; 31: 3996-4006.
15. [15]. Hsu, FY, Chen, PS, Lin, HJ, Wu, CY. 2015. Boiling Phenomena of Cooling Water in the Permanent Mold. International Journal of Metalcasting; 9: 31-40.
16. [16]. L. Katgerman. 2011. Principles of Solidification. Materials Today; 14(10): 502.
17. [17]. Warriner, WE, Monroe, CA. 2019. Open-Source MATLAB Code for Hotspot Identification and Feeder Generation. International Journal of Metalcasting; 13: 793-816.
18. [18]. Sui, D, Cui, Z, Wang, R, Hao, S, Han, Q. 2016. Effect of Cooling Process on Porosity in the Aluminum Alloy Automotive Wheel During Low-Pressure Die Casting. International Journal of Metalcasting; 10: 32-42.
19. [19]. Konrad, CH, Brunner, M, Kyrgyzbaev, K, Völkl, R, Glatzel, U. 2011. Determination of heat transfer coefficient and ceramic mold material parameters for alloy IN738LC investment castings. Journal of Materials Processing Technology; 211(2): 181-186. [20]. Sun, Z, Hu, H, Niu, X. 2011. Determination of heat transfer coefficients by extrapolation and numerical inverse methods in squeeze casting of magnesium alloy AM60. Journal of Materials Processing Technology; 211(8): 1432-1440.
20. [21]. Nişancı, MC. Batarya kalıplarında döküm-kalıp ısı transfer katsayısı hesaplanması ve yolluk tasarımı ile kalıp ısı dağılımının optimize edilmesi. MSc Thesis, Manisa Celal Bayar University, 2019; pp 124.