FMHP Modeling Design Simulation of Filing Sequence and Solidification Time for Cast Metal Matrix Composite by Low Pressure Die Casting.

Copyright © 2011 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 5, N. 2 Special Issue on Heat Transfer 273 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 10 20 30 40 50 60 70 Q W h ev W m ².K 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 h c W m ². K Thermosyphon position Anti-gravity position Horizontal position T sf = 40 °C Fig. 13. Evaporation and condensation heat transfer coefficient Vs. Q, for different orientations

IV. FMHP Modeling

The section of the FMHP is illustrated by Fig. 2 square microchannels with D g = W g = d. The liquid accumulates in the corners and forms four meniscuses Fig. 14. Their curvature radius, r c , is related to the difference of pressure, between vapor and liquid phase, by the Laplace-Young equation. Fig. 14. Evolution of the curvature radius along a microchannel In the evaporator and adiabatic zones, the curvature radius, in the parallel direction of the microchannel axis, is lower than the one perpendicular to this axis. Therefore, the meniscus is described by only one curvature radius. In a given section, r c is supposed constant. The axial evolution of r c is obtained by the differential of the Laplace-Young equation. The part of wall that is not in contact with the liquid is supposed dry and adiabatic. In the condenser, the liquid flows toward the microchannel corners. There is a transverse pressure gradient, and a transverse curvature radius variation of the meniscus. The distribution of the liquid along a microchannel is presented in Fig. 14. The microchannel is divided into several elementary volumes of length, dz, for which, we consider the Laplace-Young equation, and the conservation equations written for the liquid and vapor phases as it follows: Laplace-Young equation: 2 v l c c dP dP dr dz dz dz r σ − = − 11 Liquid and vapor mass conservation: 1 l l l v d w A dQ dz h dz ρ = ∆ 12 1 v v v v d w A dQ dz h dz ρ = − ∆ 13 Liquid and vapor momentum conservation: 2 l l l l l il il lw lw l l d A w dz dz d A P dz A A dz g A sin dz ρ τ τ ρ θ = = + + + − 14 2 v v v v v il il vw vw v v d A w dz dz d A P dz A dz A g A sin dz ρ τ τ ρ θ = = − − + − − 15 Energy conservation: 2 2 1 w w w sat w w T h dQ T T t l t dz z λ ∂ − − = − × ∂ 16 The quantity dQdz in equations 12, 13, and 16 represents the heat flux rate variations along the elementary volume in the evaporator and condenser zones, which affect the variations of the liquid and vapor mass flow rates as it is indicated by equations 12 and 13. So, if the axial heat flux rate distribution along the microchannel is given by the following Eq.17: 1 a e e a e e a e a a e a t b c b Q z L z L Q Q L z L L L L z Q L L z L L L L ≤ ≤ ⎧ ⎪ = + ⎪ ⎨ ⎛ ⎞ + − ⎪ + + ≤ ≤ − ⎜ ⎟ ⎪ − ⎝ ⎠ ⎩ 17 We get a linear flow mass rate variations along the microchannel. In equation 17, h represents the heat transfer coefficient in the evaporator, adiabatic and condenser sections. For these zones, the heat transfer coefficients Copyright © 2011 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 5, N. 2 Special Issue on Heat Transfer 274 are determined from the experimental results section 3. Since the heat transfer in the adiabatic section is equal to zero and the temperature distribution must be represented by a mathematical continuous function between the different zones, the adiabatic heat transfer coefficient value is chosen to be the average between the evaporator and condenser heat transfer coefficients in order to compute the temperature distribution corresponding to the transition from the evaporator zone to the adiabatic one, and from the adiabatic section to the condenser one. The liquid and vapor passage sections, A l , and A v , the interfacial area, A il , the contact areas of the phases with the wall, A lp and A vp , are expressed using the contact angle and the interface curvature radius by: 2 2 2 4 2 l c sin A r sin θ θ θ ⎛ ⎞ = − + ⎜ ⎟ ⎝ ⎠ 18 2 v l A d A = − 19 8 il c A r dz θ = × × × 20 16 2 lw c A r sin dz θ = 21 16 4 2 vw c A d r sin dz θ ⎛ ⎞ = − ⎜ ⎟ ⎝ ⎠ 22 4 π θ α = − 23 The liquid-wall and the vapor-wall shear stresses are expressed as: 2 1 2 lw l l l w f τ ρ = , l l el k f R = , l l hlw el l w D R ρ µ = 24 2 1 2 vw v v v w f τ ρ = , v v ev k f R = , v v hvw ev v w D R ρ µ = 25 where k l and k v are the Poiseuille numbers, and D hlw and D hvw are the liquid-wall and the vapor-wall hydraulic diameters, respectively. The hydraulic diameters and the shear stresses in equations 24 and 25 are expressed as follows: 2 2 2 2 c hlw sin r sin D sin θ θ θ θ ⎛ ⎞ × − + ⎜ ⎟ ⎝ ⎠ = 26 2 2 2 2 4 2 4 2 c hvw c sin d r sin D d sin r θ θ θ θ ⎛ ⎞ − − + ⎜ ⎟ ⎝ ⎠ = − × 27 2 1 2 2 2 2 l l l lw c k w sin sin sin r µ θ τ θ θ θ = ⎛ ⎞ − + ⎜ ⎟ ⎝ ⎠ 28 2 2 2 4 2 2 4 2 v v v c vw c k w d sin r sin d r sin µ θ τ θ θ θ ⎛ ⎞ ⎛ ⎞ − ⎜ ⎟ ⎜ ⎟ ⎝ ⎠ ⎝ ⎠ = ⎛ ⎞ ⎛ ⎞ − − + ⎜ ⎟ ⎜ ⎟ ⎝ ⎠ ⎝ ⎠ 29 The liquid-vapor shear stress is calculated by assuming that the liquid is immobile since its velocity is considered to be negligible when compared to the vapor velocity w l w v . Hence, we have: 2 1 2 v v v il eiv w k R ρ τ = , v v hiv eiv v w D R ρ µ = 30 where D hiv is the hydraulic diameter of the liquid-vapor interface. The expressions of D hiv and τ iv are: 2 2 2 2 4 2 2 c hi c sin d r sin D r θ θ θ θ ⎛ ⎞ − − + ⎜ ⎟ ⎝ ⎠ = 31 2 2 2 2 4 2 v c v v il c k r w sin d r sin θ µ τ θ θ θ = ⎛ ⎞ − − + ⎜ ⎟ ⎝ ⎠ 32 The equations 11-16 constitute a system of six first order differential, nonlinear, and coupled equations. The six unknown parameters are: r c , w l , w v , P l , P v , and T w . The integration starts in the beginning of the evaporator z = 0 and ends in the condenser extremity z = L t - L b , where L b is the length of the condenser flooding zone. The boundary conditions for the adiabatic zone are the calculated solutions for the evaporator end. In z = 0, we use the following boundary conditions: c c min r r = 33a v l w w = = 33b v sat v P P T = 33c v l c min P P r σ = − 33d The solution is performed along the microchannel if r c is higher than r cmin . The coordinate for which this condition is verified, is noted L as and corresponds to the microchannel dry zone length. Beyond this zone, the liquid doesnt flow anymore. Solution is stopped when r c Copyright © 2011 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 5, N. 2 Special Issue on Heat Transfer 275 = r cmax , which is determined using the following reasoning: the liquid film meets the wall with a constant contact angle. Thus, the curvature radius increases as we progress toward the condenser Figs. 14 a to b. When the liquid film contact points meet, the wall is not anymore in direct contact with vapor. In this case, the liquid configuration should correspond to Fig. 14 c, but actually, the continuity in the liquid-vapor interface shape imposes the profile represented on Figure 14 d. In this case, the curvature radius is maximum. Then, in the condenser, the meniscus curvature radius decreases as the liquid thickness increases Fig. 14 e. The transferred maximum power, so called capillary limit, is determined if the junction of the four meniscuses starts precisely in the beginning of the condenser.

V. Numerical Results and Analysis