Improvements on heat flux and heat conductance estimation with applications to metal castings.

摘要

Heat flux and heat conductance at the metal mold interface plays a key role in controlling the final metal casting strength. It is difficult to obtain these parameters through direct measurement because of the required placement of sensors, however they can be obtained through inverse heat conduction calculations. Existing inverse heat conduction methods are analyzed and classified into three categories, i.e., direct inverse methods, observer-based methods and optimization methods. The solution of the direct inverse methods is based on the linear relationship between heat flux and temperature (either in the time domain or in the frequency domain) and is calculated in batch mode. The observer-based method consists on the application of observer theory to the inverse heat conduction problem. The prominent characteristic in this category is online estimation, but the methods in this category show weak robustness. Transforming estimation problems into optimization problems forms the methods in the third category. The methods in third category show very good robustness property and can be easily extended to multidimensional and nonlinear problems. The unknown parameters in some inverse heat conduction methods can be obtained by a proposed calibration procedure. A two-index property evaluation (accuracy and robustness) is also proposed to evaluate inverse heat conduction methods and thus determine which method is suitable for a given situation. The thermocouple dynamics effect on inverse calculation is also analyzed. If the thermocouple dynamics is omitted in the inverse calculation, the time constant of thermocouple should be as small as possible. Finally, a simple model is provided simulating the temperature measurement using a thermocouple. FEA (Finite Element Analysis) is employed to simulate temperature measurement.