This document describes the development of an algorithm to calculate the interfacial heat transfer coefficient (IFHTC) for a sand casting process. The algorithm is developed through ANSYS simulations of heat transfer during casting of an aluminum plate. Two meshing techniques, free mesh and mapped mesh, are used. The inverse heat conduction method is applied to calculate IFHTC from heat flux and temperature difference data. IFHTC is calculated for different pouring temperatures and an algorithm is developed and coded in Java. Results from the algorithm match well with ANSYS simulations, with less than 2.5% error. Future work may involve extending the algorithm to other materials, shapes, and optimizing additional casting parameters.

1. DEVELOPMENT OF AN
ALGORITHM OF INTERFACIAL
HEAT TRANSFER COEEFICIENT
GROUP NO:- 03
SWAPNIL PATIL 201042
ANUSHA PUTTI 201044
MAYUR RATHOD 201046
SNEHA MORE 201071
PROJECT GUIDE: Mr. C. M. CHOUDHARI

2. AIM AND OBJECTIVE:-
Develop an algorithm for Interfacial Heat Transfer
Coefficient (IFHTC).
Objective:-
1. To find the heat transfer coefficient for the air gap
formed.
2. To find the optimum pouring temperature for good
quality casting
3. To develop an algorithm for the same

3. PROBLEM DEFINITION:-
 To develop an algorithm for interfacial heat transfer
coefficient.

4. SCOPE
 The project deals with only sand casting and
considering Aluminum as the cast material.
 The shape of the component considered is a simple
plate.
 Except for the air gap formation other defects are not
taken into consideration.
 Analysis performed is only in 2D.

5. CASTING SPECIFICATIONS
 Mould dimensions: 300 x 300 x 180 mm
 Cavity dimensions: 200x200x40 mm
 Material used: Aluminum
 Type of casting: Sand casting

6. ANSYS WORK
Simulation done by two methods
1. Free Mesh.
2. Mapped Mesh.

7. FINAL SIMULATION OF MAPPED
MESH

8. INVERSE HEAT CONDUCTION
 h = q /∆T
 q =K dt/dx
h = Interfacial heat transfer coefficient
q = Heat flux
K = Thermal conductivity
dt = Difference between pouring temperature
and mould temperature.
dx = 0.5 m

9. RESULTS OF HEAT TRANSFER
COEFFICIENT ACCORDING TO
POURING TEMPERATURE
Pouring temperature
(K)
Thermal conductivity
(W/m K)
Heat transfer coefficient
(W/m²K)
933 90.7 17447.633
973 92.1 17505.532
1073 95.5 18156.760
1173 98.6 18547.460

10. GRAPH OF POURING TEMPERATURE
VS
HEAT TRANSFER COEFFICIENT
17200
17400
17600
17800
18000
18200
18400
18600
18800
850 900 950 1000 1050 1100 1150 1200
Heattransfercoefficient(W/m²K)
Pouring temperature (K)
heat transfer coefficient

11. ALGORITHM

12. ALGORITHM CALCULATION

13. ALGORITHM INPUTS
• Surface area of casting = 2(200*200+200*40+200*40)
• Volume of casting = 200*200*40
• Density of aluminium = 2700 Kg/m3
• Specific heat capacity = 0.91 KJ/kgK

14. RESULTS OBTAINED FROM
ALGORITHM
Pouring
temperature
(K)
Thermal
conductivity
(W/m K)
Heat transfer
coefficient
(W/m²K)
933 90.7 17000
973 92.1 17105
1073 95.5 17800
1173 98.6 18100

15. EXECUTION OF ALGORITHM IN JAVA

16. COMPARISON OF RESULTS
OBSERVATION
NO.
POURING
TEMPERATURE
SIMULATION
RESULTS
ALGORITHM
RESULTS
% ERROR
1 933 17447.633 17000 2.56
2 973 17505.532 17105 2.28
3 1073 18156.760 17800 1.96
4 1173 18547.460 18100 2.41

17. FUTURE SCOPE
• It can be extended to castings of different materials
and of different shapes.
• The analysis can also be done to find the other
optimum parameters for casting process such as
pouring temperature.
• The analysis can also be done for 3-D.

18. THANK YOU