Artificial intelligence assisted calculation of interfacial heat transfer coefficient in low pressure die castings

The interfacial heat transfer coefficient (IHTC), or contact thermal resistance, characterizes the heat transfer characteristics between two contacting objects. During the casting process, the cooling of the molten metal in the mold cavity relies mostly on the heat transfer between the metal and the mold. Therefore, the IHTC between the mold and the casting is crucial for the accurate prediction of temperature distribution in a casting component. In this study, a new methodology has been developed to obtain the full sets of IHTC in complex castings like wheel hubs. Using limited experimental data and finite element simulation results, such artificial algorithms as XGBoost, SVR, and Transformer have been applied to establish the correlation between output temperature distribution and input IHTC. It has been found that the XGBoost model performed best, which was then used as the objective function in a non-dominated sorting genetic algorithm (NSGA II) optimization. Therefore, accurate simulations have been performed by applying specific IHTC to different boundaries, enabling successful validation by experimental data from thermocouple measurements.