Development and Characterisation of a New Die-Casting Die Cooling System Based on Internal Spray Cooling
Abstract
:1. Introduction
2. Theoretical Background and Methods for Describing Spray Cooling
2.1. Influencing Factors on the Heat Transfer of a Spray Cooling
2.2. Characterisation of the Spray Flow
2.3. Temperature Change Rates
3. Development of a Masked Mould with Internal Spray Cooling
3.1. Conception of the Experiment Mould and Design of the Casting
3.2. Design of the Cooling Systems
3.3. Simulation Workflow
3.4. Integration of Spraying and Measuring Technology
4. Experimental Setup and Test Procedure
5. Results and Discussion
5.1. Analysis of the Tempering and Reaction Behaviour of the Mould
5.2. Temperature Change Rates
5.2.1. Temperature Change Rates as a Function of Pressure for Cool-Spray
5.2.2. Analysis of the Cooling Performance
5.2.3. Comparison with Conventional Cooling
5.3. Influenceability of Component Quality
6. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Process Steps | Duration in s | Description |
---|---|---|
pouring | manually using a pouring ladle | |
solidification | visual inspection of the solidification status | |
die open | hydraulic and manual control | |
ejection | hydraulic and manual control | |
part removal | manual with foundry tongs | |
return ejector | hydraulic and manual control | |
die close | hydraulic and manual control | |
waiting and preparation | scooping with a pouring laddle | |
total cycle |
Cool-Spray | Conventional Cooling | |
---|---|---|
set temperature | 250 °C | 200 °C |
medium | water, 20 °C | heat transfer oil |
flow rate | variable | 16–17 L/min |
pressure | 4 bar | 5 bar |
duty cycle | 20% | - |
frequency | 5 Hz | - |
(a) Reference | (b) Gradient | (c) Gradient and Delay | |
---|---|---|---|
Cool-Spray | |||
conventional | - | ||
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Haban, A.; Kracun, S.F.; Rohde, D.N.; Fehlbier, M. Development and Characterisation of a New Die-Casting Die Cooling System Based on Internal Spray Cooling. Metals 2024, 14, 956. https://doi.org/10.3390/met14090956
Haban A, Kracun SF, Rohde DN, Fehlbier M. Development and Characterisation of a New Die-Casting Die Cooling System Based on Internal Spray Cooling. Metals. 2024; 14(9):956. https://doi.org/10.3390/met14090956
Chicago/Turabian StyleHaban, Alexander, Stefanie Felicia Kracun, Danny Noah Rohde, and Martin Fehlbier. 2024. "Development and Characterisation of a New Die-Casting Die Cooling System Based on Internal Spray Cooling" Metals 14, no. 9: 956. https://doi.org/10.3390/met14090956