Aluminum Sand Casting Interfacial Heat Flux Estimation Based on Corrected Temperature Measurements
Jonathan W. Woolley and Keith A. Woodbury
International Mechanical Engineering Congress and Exposition
Boston, Massachusetts, October 31 - November 6, 2008
ABSTRACT
The estimation of the heat flux at the
interface between a solidifying metal casting and mold is a frequently
investigated topic.Accurate knowledge
of the interfacial heat transfer can be used in solidification simulation to
reduce the time and cost of the casting design process.A common and well-established approach to
estimating the interfacial heat flux is the solution of the inverse heat
conduction problem.Temperature
measurements from thermocouples imbedded in the sand mold are used as inputs to
the inverse solver.It is
well-documented that imbedded thermocouples which are subjected to high
temperature gradients will yield biased temperature measurements.By accounting for the sensor dynamics with an
appropriate model, the measured temperatures can be corrected to mitigate the
effect of the bias error in the estimation of the heat flux.
In a previous work, experimentally measured
temperatures were obtained from aluminum sand castings and the interfacial heat
transfer was evaluated.In other works,
the temperature measurement error was demonstrated and the kernel method for
correcting measured temperatures was demonstrated with a numerical
experiment.In this paper, the
simulation of the response of a thermocouple with a three-dimensional
computational model is used with the kernel method to correct the
experimentally measured temperatures.The previous interfacial heat flux estimates are updated by solving the
inverse heat conduction problem with the corrected temperatures as the inputs.
