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Numerical Analysis of the Cooling System Performance and Effectiveness in Aluminum Low-Pressure Die Casting

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Abstract

This study was carried out to determine the parameters affecting the performance of ring-type air cooling channels used in low-pressure die casting method for aluminum wheel casting. The main purpose of this study is to reveal the working principles of air cooling used in wheel casting. The study was conducted using computational fluid dynamics software. Field verification was performed before different numerical experiments. Then, flow rate was measured with different numerical experiments by changing the number of cooling inlets, number of cooling outlets and cooling pressure of the cooling channel. Experiments with numerical methods were examined statistically. The results showed that the flow rate of the cooling air is affected by the inlet count, the pressure of the cooling channel and the ratio between the inlet and outlet areas. Cooling system would contain air pressure of 6 bar, maximum outlet count of 12 and inlet count of 2 for optimum cooling performance and effectiveness. Ai/Ao ratio was found as 0.5 for maximum mass flow to this cooling system.

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Acknowledgements

We would like to express our appreciation to Eren Bozkurt for his help in validation study. We would also express that this article is produced from the studies in the Master’s thesis of Hakan Yavuz.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, Izmir Katip Celebi University, 35620, Izmir, Turkey

    Hakan Yavuz & Onur Ertugrul

  2. CMS Light Alloy Wheels Co. R&D Center, Çiğli, Izmir, Turkey

    Hakan Yavuz

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  1. Hakan Yavuz
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  2. Onur Ertugrul
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Correspondence to Hakan Yavuz.

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Yavuz, H., Ertugrul, O. Numerical Analysis of the Cooling System Performance and Effectiveness in Aluminum Low-Pressure Die Casting. Inter Metalcast 15, 216–228 (2021). https://doi.org/10.1007/s40962-020-00446-x

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