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© All material copyright Shiloh and should be considered confidential and not for distribution. 1 High performance cooling system of the die cast dies.

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Presentation on theme: "© All material copyright Shiloh and should be considered confidential and not for distribution. 1 High performance cooling system of the die cast dies."— Presentation transcript:

1 © All material copyright Shiloh and should be considered confidential and not for distribution. 1 High performance cooling system of the die cast dies

2 © All material copyright Shiloh and should be considered confidential and not for distribution. 2 Objectives: 1. Improve performance of the die cast die cooling system 2. Reduce soldering of the die components 3. Reduce solidification shrinkage defects 3. Improve micro-structure of the casting High performance cooling system of the die cast dies

3 © All material copyright Shiloh and should be considered confidential and not for distribution. 3 Typical cooling system layout High performance cooling system of the die cast dies

4 © All material copyright Shiloh and should be considered confidential and not for distribution. 4 Stages of the boiling process Convective heat transfer mode Nucleate boiling Steam jets are forming Neighboring vapor jets merge Most of the surface of the heated wall is covered with vapor High performance cooling system of the die cast dies

5 © All material copyright Shiloh and should be considered confidential and not for distribution. 5 Heat transfer coefficient distribution along the channel length Zone IConvection heat transfer Zone IINucleate boiling Zone IIIMost of the surface of the heated wall is covered with vapor Zone IVTransition boiling Zone VFilm boiling High performance cooling system of the die cast dies

6 © All material copyright Shiloh and should be considered confidential and not for distribution. 6 There are substantial differences between the two phase flow in micro-channels and conventional cooling channels 1. Surface tension force has a more pronounced influence on the flow. 2. Bubbly flow can be rarely observed because bubbles grow and quickly reach size of the channel. 3. Due to small size of the channel Taylor instability doesnt occur in the micro-channels. High performance cooling system of the die cast dies

7 © All material copyright Shiloh and should be considered confidential and not for distribution. 7 Boiling in thin channel Zone IConvection heat transfer Zone IINucleate boiling Zone IIIMost of the surface of the heated wall is covered with vapor Zone IVTransition boiling Zone VFilm boiling High performance cooling system of the die cast dies

8 © All material copyright Shiloh and should be considered confidential and not for distribution. 8 Full shot with core High performance cooling system of the die cast dies

9 © All material copyright Shiloh and should be considered confidential and not for distribution. 9 Core with micro-channel cooling High performance cooling system of the die cast dies

10 © All material copyright Shiloh and should be considered confidential and not for distribution. 10 Stress analysis of the core(dyne/cm^2) High performance cooling system of the die cast dies

11 © All material copyright Shiloh and should be considered confidential and not for distribution. 11 Temperature distribution in the core (Before spray) High performance cooling system of the die cast dies

12 © All material copyright Shiloh and should be considered confidential and not for distribution. 12 Core after 6,000 shots High performance cooling system of the die cast dies Old cooling channel designMicro-channel cooling design

13 © All material copyright Shiloh and should be considered confidential and not for distribution. 13 Heat transfer coefficient for micro-channel cooling Heat transfer coefficient is found by a superposition of the nucleate boiling and forced convection components 1. High performance cooling system of the die cast dies Where, S - suppression factor h nb - nucleate boiling heat transfer coefficient F - enhancement factor h sp - single phase heat transfer coefficient 1. J.C. Chen, Correlation for boiling heat transfer to saturated fluids in convective flow, Industrial and Engineering Chemistry – Process Design and Development5 (3) (1966) 322–329.

14 © All material copyright Shiloh and should be considered confidential and not for distribution. 14 Verification of the numerical analysis results High performance cooling system of the die cast dies

15 © All material copyright Shiloh and should be considered confidential and not for distribution. 15 High performance cooling system of the die cast dies Smaller core with cooling (Dia. 12 mm)

16 © All material copyright Shiloh and should be considered confidential and not for distribution. 16 High performance cooling system of the die cast dies Smaller core with cooling (Dia. 12 mm)

17 © All material copyright Shiloh and should be considered confidential and not for distribution. 17 High performance cooling system of the die cast dies Rib insert with micro-channel cooling

18 © All material copyright Shiloh and should be considered confidential and not for distribution. 18 High performance cooling system of the die cast dies Old cooling line designMicro-channel cooling

19 © All material copyright Shiloh and should be considered confidential and not for distribution. 19 High performance cooling system of the die cast dies Conclusions 1.Three dimensional micro-channel cooling is an affective high capacity thermal management method. It can support high heat transfer rates from the liquid metal during metal flow and solidification. 2.Reduction in core heat resistance as well as increase of thermal capacity of the cooling system, allows support of higher heat flux without over-heating of the core 3.New cooling design concepts allowed further reduction or even elimination of die soldering, casting surface defects, and excessive external cooling while reducing cycle time and cost

20 © All material copyright Shiloh and should be considered confidential and not for distribution. 20 High performance cooling system of the die cast dies Questions?


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