Conformal cooling of aluminium flat fins using a 3-D printed water-cooled mould

Research output: Contribution to conferencePaper

Abstract

The cooling phase within the high-pressure injection moulding process is critically important to produce good quality parts in minimum cycle time and to maximise the tool life. Modelling the cooling process in the mould during the casting process is very complex and required high computation resources which could be challenging especially, when examining various design parameters. In this work, a simple model has been developed based on experimental work that shows the interface temperature during the cooling process inside the mould remains almost constant until the mould is opened. Based on this observation, the heat flux generated from a generic shape of a molten aluminium alloy flat fin to achieve a uniform temperature at its outer surface is evaluated assuming steady state condition during the moulding time. A conjugate steady heat transfer model has been developed using a 3-D CFD model that utilizes RANS together with Low-Reynolds Number k- turbulence model to evaluate the cast-tool interface heat flux distribution assuming the pre-defined interface temperature. It was therefore economically possible to evaluate the effect of cooling flow velocity and channel location and layout on the cooling rate and the heat flux with a limited computation resource. The high heat flux at the corners of the fins was evaluated and effect of various fillets showed there is an optimum radius to achieve minimum average heat flux in the corner area. It was concluded that the new method can provide the necessary information for the initial design of the cooling channels for various fins thickness before a final optimization method can be implemented. The model result was in close agreement with a full transient model that includes the molten aluminium, the mould and cooling water.
Original languageEnglish
Number of pages3
Publication statusPublished - 10 Sep 2019
EventUK Heat Transfer Conference - Nottingham University, Nottingham, United Kingdom
Duration: 8 Sep 201910 Sep 2019
Conference number: 16
https://www.nottingham.ac.uk/conference/fac-eng/ukhtc2019/index.aspx

Conference

ConferenceUK Heat Transfer Conference
Abbreviated titleUKHTC
CountryUnited Kingdom
CityNottingham
Period8/09/1910/09/19
Internet address

Fingerprint

Fins (heat exchange)
Heat flux
Cooling
Aluminum
Water
Molten materials
Compression molding
Cooling water
Turbulence models
Injection molding
Flow velocity
Molding
Temperature
Aluminum alloys
Computational fluid dynamics
Casting
Reynolds number
Heat transfer

Cite this

Liang, Y., Sharma, R., Abo-Serie, E., & Jewkes, J. (2019). Conformal cooling of aluminium flat fins using a 3-D printed water-cooled mould. Paper presented at UK Heat Transfer Conference, Nottingham, United Kingdom.

Conformal cooling of aluminium flat fins using a 3-D printed water-cooled mould. / Liang, Yuancheng; Sharma, R; Abo-Serie, Essam; Jewkes, James.

2019. Paper presented at UK Heat Transfer Conference, Nottingham, United Kingdom.

Research output: Contribution to conferencePaper

Liang, Y, Sharma, R, Abo-Serie, E & Jewkes, J 2019, 'Conformal cooling of aluminium flat fins using a 3-D printed water-cooled mould' Paper presented at UK Heat Transfer Conference, Nottingham, United Kingdom, 8/09/19 - 10/09/19, .
Liang Y, Sharma R, Abo-Serie E, Jewkes J. Conformal cooling of aluminium flat fins using a 3-D printed water-cooled mould. 2019. Paper presented at UK Heat Transfer Conference, Nottingham, United Kingdom.
Liang, Yuancheng ; Sharma, R ; Abo-Serie, Essam ; Jewkes, James. / Conformal cooling of aluminium flat fins using a 3-D printed water-cooled mould. Paper presented at UK Heat Transfer Conference, Nottingham, United Kingdom.3 p.
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abstract = "The cooling phase within the high-pressure injection moulding process is critically important to produce good quality parts in minimum cycle time and to maximise the tool life. Modelling the cooling process in the mould during the casting process is very complex and required high computation resources which could be challenging especially, when examining various design parameters. In this work, a simple model has been developed based on experimental work that shows the interface temperature during the cooling process inside the mould remains almost constant until the mould is opened. Based on this observation, the heat flux generated from a generic shape of a molten aluminium alloy flat fin to achieve a uniform temperature at its outer surface is evaluated assuming steady state condition during the moulding time. A conjugate steady heat transfer model has been developed using a 3-D CFD model that utilizes RANS together with Low-Reynolds Number k- turbulence model to evaluate the cast-tool interface heat flux distribution assuming the pre-defined interface temperature. It was therefore economically possible to evaluate the effect of cooling flow velocity and channel location and layout on the cooling rate and the heat flux with a limited computation resource. The high heat flux at the corners of the fins was evaluated and effect of various fillets showed there is an optimum radius to achieve minimum average heat flux in the corner area. It was concluded that the new method can provide the necessary information for the initial design of the cooling channels for various fins thickness before a final optimization method can be implemented. The model result was in close agreement with a full transient model that includes the molten aluminium, the mould and cooling water.",
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AB - The cooling phase within the high-pressure injection moulding process is critically important to produce good quality parts in minimum cycle time and to maximise the tool life. Modelling the cooling process in the mould during the casting process is very complex and required high computation resources which could be challenging especially, when examining various design parameters. In this work, a simple model has been developed based on experimental work that shows the interface temperature during the cooling process inside the mould remains almost constant until the mould is opened. Based on this observation, the heat flux generated from a generic shape of a molten aluminium alloy flat fin to achieve a uniform temperature at its outer surface is evaluated assuming steady state condition during the moulding time. A conjugate steady heat transfer model has been developed using a 3-D CFD model that utilizes RANS together with Low-Reynolds Number k- turbulence model to evaluate the cast-tool interface heat flux distribution assuming the pre-defined interface temperature. It was therefore economically possible to evaluate the effect of cooling flow velocity and channel location and layout on the cooling rate and the heat flux with a limited computation resource. The high heat flux at the corners of the fins was evaluated and effect of various fillets showed there is an optimum radius to achieve minimum average heat flux in the corner area. It was concluded that the new method can provide the necessary information for the initial design of the cooling channels for various fins thickness before a final optimization method can be implemented. The model result was in close agreement with a full transient model that includes the molten aluminium, the mould and cooling water.

M3 - Paper

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