Calculating the heat transfer coefficient of the casting-mold in the mold of the faucet and optimize the heat distribution with new design of the feeder

The faucets in the sanitary tapware can mix Hot and cold water with the desired proportions and can drain. Today, the raw material of the faucets is generally brass alloy and is produced by using low pressure die casting or hot forging method. The seen mistakes in the faucet produced by the low pressure die casting method are shrinkage, pore, gas gap, crack, spongy structure etc. These mistakes cause the part to be scrapped. When the cauese of faults are examined, it is understood that there are general faults caused by heat. Due to such mistakes; In the pressure casting method, the determination of the heat-transfer coefficient of the die-casting interface is very important for the quality of the cast. The heat transfer coefficient of the casting-mold interface varies depending on the mold temperature, the casting temperature, the injection pressure, the injection speed, the mold surface roughness, the mold design and the alloy type. In this study, the experimental production was realized and the temperatures of the experimental production in the process time had recorded by the thermocouples which are connected to the mold of the faucet. Thermal analysis was performed by using Fluent module in Ansys program. The heat transfer coefficient of the interface was calculated numerically by thermal analysis. The calculated heat transfer coefficient was defined in the Magma program and the casting simulation was run. The temperature curves of the simulation studies using the determined heat transfer coefficient values and the temperature curves obtained during the experimental production were converged. Then, the locations and values of the faulty zones formed as a result of the simulation were compared with the mistakes in the experimental production and the mistakes were overlapped. As a result, with the mistakes in the current production and the simulation mistakes, the simulation was repeated by changing the gating design in another model, and the mistakes resulting from the simulation were examined.