Djabraian Serouj, Teichmann Fabian, Müller Sebastian
Institute of Casting Technology, Friedrich-Alexander-Universität Erlangen-Nürnberg, Dr.-Mack-Str. 81, 90762 Fürth, Germany.
Materials (Basel). 2024 Apr 30;17(9):2114. doi: 10.3390/ma17092114.
Conventional cooling channels used in die casting molds exhibit significant drawbacks, resulting in extended cooling times for cast parts. Issues such as the formation of dirt, limescale, and corrosion substantially diminish the thermal efficiency of these channels, leading to challenges in achieving uniform cooling and potential quality issues. In response to these challenges, this study proposes Topology Optimization as a novel approach. It involves designing cooling structures through Topology Optimization to replace traditional cooling channels, incorporating both Discrete and Gaussian boundary conditions to optimize thermal efficiency. Additionally, Structural Topology Optimization is employed to ensure structural integrity, preventing deformation or yielding under high loads during the die casting process. Numerical analysis revealed superior thermal performance compared to conventional channels, particularly when subjected to Discrete and Gaussian boundary conditions. Furthermore, the application of the latter establishes conformal cooling and minimizes temperature gradients in the casting, reducing casting defects such as shrinkage porosity. These findings highlight the efficacy of Topology Optimization in addressing the challenges of traditional cooling methods, with wide-ranging implications for manufacturing processes utilizing permanent molds for shaping materials.
压铸模具中使用的传统冷却通道存在显著缺点，导致铸件冷却时间延长。污垢、水垢和腐蚀的形成等问题会大幅降低这些通道的热效率，导致在实现均匀冷却方面面临挑战，并可能引发质量问题。针对这些挑战，本研究提出将拓扑优化作为一种新方法。它涉及通过拓扑优化设计冷却结构，以取代传统冷却通道，同时纳入离散和高斯边界条件以优化热效率。此外，采用结构拓扑优化来确保结构完整性，防止在压铸过程中高负荷下发生变形或屈服。数值分析表明，与传统通道相比，其热性能更优，尤其是在离散和高斯边界条件下。此外，后者的应用实现了共形冷却，并使铸件中的温度梯度最小化，减少了诸如缩松等铸造缺陷。这些发现凸显了拓扑优化在应对传统冷却方法挑战方面的有效性，对利用永久模具成型材料的制造工艺具有广泛影响。
