Course:MTRL467 Finger Cooling Heat Transfer

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General Information

This is a design project in course MTRL467 in the spring term of year 2020.

The proposed project title is "Design of a laboratory system to characterize heat transfer of the “finger” cooling configuration in permanent die casting".

Expectations

  • Students are expected to drive the process and act as consultants and the supervisors as customers
  • All the data related to die design and process parameters should be kept in confidence

Contact

  • Daan Maijer (Professor): Frank Forward room 313; daan.maijer@ubc.ca; 604-822-6013
  • Jun Ou (Research Associate): Frank Forward room 105; jun.ou@ubc.ca; 604-827-2155

When you contact us by email, please include both of us in your email.

Office hours

  • Not set up. If you need a in-person discussion:
    • for any technical questions, you can try to find Jun in his office anytime, or email or call Jun to set up a time to meet.
    • for any questions, you can email or call Daan to set up a meeting.

Group Members

  • Huayu
  • Rohan
  • Bhakthie
  • Leonardo
  • Yaning
  • Andrew

Weekly Meetings

Meeting Time and Location

  • Location: Frank Forward room 313 (Daan's office)
  • Time: Friday 9:30 - 10:00 am

Please be on time as Daan has stacked meeting in Friday morning and we need to finish on time.

Meeting Minutes

Download the meeting minute template

Note: please email a copy of the meeting minutes.

The link opens a Google Drive folder where all of the meeting minutes can be found.

Project Information

Background

The casting industry has been moving toward adopting knowledge- and database-driven design approaches from the traditional experience-based design methodology. For example, utilizing process simulation and optimization tools to achieve improved/optimized die design and process operation. These new approaches expose the need to quantitatively characterize the key process phenomena that occur during the casting process.

Cooling is one of the most important process parameters to control the casting process, since it is strongly related to the defect control, production rate and microstructure of the castings. Finger cooling with water is a commonly used cooling configuration in die casting processes for the production of aluminum automotive parts. Finger cooling provides localized and efficient cooling to extract heat from the casting die for the control of solidification. In this project, a lab apparatus will be designed and manufactured to quantify the heat transfer of the finger cooling configuration, which will provide valuable data for the industrial sponsor to aid in their die and process design activities.  

Project Objective

Design a laboratory system to quantitatively characterize the heat transfer of the finger cooling configuration used in die casting processes

Design tasks

  • Design a system to characterize the heat transfer of the finger cooling configuration.
    • H13 tool steel block and finger cooling insert (will be provided)
    • Heating system *
    • Data acquisition system (temperature) *

* Note: students may design the sub-systems based on existing work in the Advanced Metal Processing group

  • Purchase or work with the department machine shop to manufacture the necessary parts
  • Assemble the system and conduct tests to make sure it meets the design requirements
  • Conduct a set of experiments to collect data if time permits
  • Generate a technical report to deliver your engineering design

Key Timelines

  • Overview session: 2020 Jan 8th
  • First meeting: 2020 Jan 17th
  • Project Proposal Report: 2020 Jan 24th, 3pm
  • Midterm - Submit Presentation Slides: Thurs Feb 6th, 12pm
  • Midterm - Presentation: Fri Feb 7th, 8am-11am
  • Midterm - Report: Mon Feb 10th, 11pm
  • Final – Submit Poster + Presentation Slides: Thurs April 2nd, 12pm
  • Final – Presentation: Fri April 3rd, 8am – 11am
  • Final – Report Mon: April 6th, 11pm
  • Design and Innovation Day – Poster Presentation Time: Tues April 7th, afternoon

Literature and Other Useful Information

Publications

Note: you should be able to download for free using UBC internet (or UBC VPN)

Characterization of heat transfer and its effect on solidification in water cooled LPDC of wheels

Process Modeling of Low-Pressure Die Casting of Aluminum Alloy Automotive Wheels

Videos

Permanent Mold Low Pressure Die Casting Animation

System Design

To be added by students during the course - please do NOT release any information related to die design and process parameters

The following systems are to be designed and manufactured

  • Heating System
  • DAQ System
  • Others, e.g. water supply, etc

Note: detailed design are not shared here for confidentiality.

Part List

To be added

System Manufacturing

Parts can be purchased by the department store or manufactured by the department machine shop.

Procedures

After your design is finalized and approved, for:

  • Purchasing:
    • Part list (vendor, specs, quantity, price) -> approval from Daan or Jun -> fill the standard form (please leave the speedchart code blank) -> send to Jun (please copy to Daan) -> Jun sends to the store with the speedchart.
    • Note:
      • The speedchart is a code for the account to be charged. Jun will provide the store which speedchart to be used for the purchasing
      • Download the standard form: File:Form ORDERS THROUGH STORES.docx
      • Contact: 604-822-2716, FrankForward 06-stores, mtrl.stores@ubc.ca
  • Machining:
    • Detailed machining drawings - approval from Daan or Jun -> send to the department machine shop
    • Note:
      • Undergraduate student projects have the highest priority for the machine shop
      • Contact: 604-822-2605, FF017

Vendors (Selected)

You are not limited to these vendors

  • https://www.mcmaster.com/
    • Pros: wide categories, well organized, CAD file available, ship fast, very responsive
    • Cons: in US dollars, relatively expensive, shipping fee is relatively high
  • https://www.omega.ca/en/
    • Pros: N/A
    • Cons: N/A
  • https://www.new-line.com/ (for hose and fittings)
    • Pros: local vendor, cost effective (UBC discount applicable)
    • Cons: shipping takes up to 1 week

Questions

  • Q: Software for the simulation of heat transfer for the project.
    • It is recommended to use Abaqus or Ansys as UBC/MTRL has their licenses.
    • If you need the installation files and instruction for the installation, please bring a USB stick/hard drive with at least 8G free space to Jun.