Thermal Optimisation Model for Cooling Channel Design Using the Adjoint Method in 3D Printed Aluminium Die-Casting Tools

Abstract In the present study, adjoint method is introduced to optimisation of corner cooling element in two baseline designs for a mould cavity, as examples Aluminium metal die-casting process. First, steady thermal model simulating process two-corner design scenario. This serves first iteration optimised using method. A dual-parameter objective function targets interfacial temperature standard deviation and pressure drop across internal region. For both cases, multi-iterative deformation cycles configurations result with non-uniform cross-section geometries smooth surface finishing. Numerical simulations resulting show improvements uniform mould/cast contact by 66.13% 92.65%, while increases coolant fluid flow 25.81% 20.35% respectively. technique has been applied optimise complex system an industrial high-pressure aluminium (HPADC) tool (Zeng et al. SAE Technical Paper 2022-01-0246, 2022, [1]). Production line experience demonstrates that have three times operational life compared conventional designs, providing significant reduction manufacturing operation costs.