1. Modeling Cooling Channels with FLOW-3D® Cast 3.1.1 2009-02-06 Tuomas Tynjälä Simtech Systems Inc.

2. Modeling cooling channels There are two methods for modeling cooling channels 1) By using obstacles with constant surface temperature Supports time depended temperatures Supports time depended temperatures Easy to model Easy to model Channel is not visualized as hollow in postprocessing Channel is not visualized as hollow in postprocessing 2) By using gas (void) regions Supports emissivity Supports emissivity Without tweaking, can only define 3 channels with different properties Without tweaking, can only define 3 channels with different properties

3. Cooling channels as obstacles Define casting piece, feeding channels and the mould normally. Import cooling channel geometry as STL

4. Cooling channels as obstacles In geometry interpretation create a new solid interpretation and name it as – for example – 'Channel' Assign the channel STL to this new interpretation

5. Cooling channels as obstacles In solid objects dialog Select 'Generic heat source/sink' as the material for the Channelel Select 'Generic heat source/sink' as the material for the Channelel Define the Channel as heat source/sink with surface temperature specified Define the Channel as heat source/sink with surface temperature specified Using heat flow timetable button define channel temperature as a function of time Using heat flow timetable button define channel temperature as a function of time

6. Cooling channels as obstacles In Heat transfer coefficients dialog define HTC between the mould and the Channel

7. Cooling channels as void regions Define casting piece, feeding channels and the mould normally. Import cooling channel geometry as STL

8. Cooling channels as void regions In geometry interpretation use 'New' button to create a new gas region Assign the geometry interpretation to this new geometry

9. Cooling channels as void regions In Flow->Gas Regions set properties for the cooling channel. Check Heat Transfer [ivht] flag, leave type as 1 Check Heat Transfer [ivht] flag, leave type as 1 Set temperature [tvrd] as the channel temperature Set temperature [tvrd] as the channel temperature

10. Cooling channels as void regions In Heat transfer coefficients dialog define heat transfer coefficient and emissivity coefficient between mould and void 1