Cooling Channels

Cooling channel simulation using FLOW-3D

Cooling channel simulation using FLOW-3D

Cooling channels are used in die casting and permanent mold casting for thermal management of the process to prevent the overheating of the die and to control the solidification of the casting. FLOW-3D‘s cooling channel model offers a wide range of features, allowing users to accurately capture the complex behavior of the modern systems, assuring an optimum design and casting properties.

Model Highlights

  • Time-dependent temperature and heat transfer coefficients
  • Thermocouple-controlled activation for cooling and heating
  • Performance diagnostics

Thermal Die Cycling Simulations

Thermal die cycling simulations are used for obtaining the die temperature after running a number of parts and a quasi-steady state condition is achieved. This type of simulation helps determine if there is sufficient cooling to extend the life of the die, and ensure no defects will occur in the final cast part. In this example, the feature of time-controlled cooling channel activation is demonstrated. Ten cycles were run where each cycle contained the following stages: after filling for duration of solidification, die opening, die spraying, and dwell time before die closes. Cooling lines in the ejector and cover of the die are on constantly while the “dead-end” cooling lines are only on during the first stage. Below is an image of the part and cooling lines with a description of duration of time on, initial temperatures, and heat transfer coefficients that were determined from equations of flow through a pipe.

Casting and cooling channel locations and properties

Casting and cooling channel locations and properties. Blue cooling lines have an initial temperature of 25°C, heat transfer coefficient to the die of 5.14e6 erg/s-cm2-K and are on throughout the entire simulation. Pink cooling lines have initial temperature of 65°C, heat transfer coefficient to the die of 5.14e6 erg/s-cm2-K, and are on throughout entire simulation. Red cooling lines have an initial temperature of 25°C and a heat transfer coefficient of 4.13e+06 erg/s-cm2-K and are on only during the first 25.5 seconds during the solidification stage.

This video shows a slice through the die, colored by the wall temperature, for 10 cycles. The slice was chosen to show the core cooling channels on during the first stage and off during the other stages in a cycle.