In the process of high pressure die casting a problem occurs when cooling the dies of a highly complicated product, as the number of “jet cooling” (combined water-air cooling system) cores is limited to 16 per tool. That is why we designed an alternative to cooling thin ribs with inserting copper cores in the centre, which will help in faster heat dissipation. We constructed three different variations of ribs and completed an analytical calculation to confirm our predictions. Then we performed numerical analysis with finite element method on all three models, to evaluate the effectiveness of heat transfer within the ribs. The ribs with copper cores are less effective than the one with cooling channels. The thicker copper core is more effective than the thinner core.
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