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

Year 2020, Volume: 16 Issue: 2, 169 - 181, 24.06.2020

Murat Can Nişancı Ali Yurddaş

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.

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