Acta Metall. Sin.(Engl. Lett.)Vol.22 No.1 pp13-21 Feb.

2009

Application of orthogonal experimental design and Tikhonov regularization method for the identication of parameters in the casting solidication process
Dashan SUI

and Zhenshan CUI

National Die & Mould CAD Engineering Research Center, Shanghai Jiaotong University, Shanghai 200030, China Manuscript received 6 March 2008; in revised form 12 June 2008 The inverse heat conduction method is one of methods to identify the casting simulation parameters. A new inverse method was presented according to the Tikhonov regularization theory. One appropriate regularized functional was established, and the functional was solved by the sensitivity coecient and Newton-Raphson iteration method. Moreover, the orthogonal experimental design was used to estimate the appropriate initial value and variation domain of each variable to decrease the number of iteration and improve the identication accuracy and eciency. It illustrated a detailed case of AlSi7Mg sand mold casting and the temperature measurement experiment was done. The physical properties of sand mold and the interfacial heat transfer coecient were identied at the meantime. The results indicated that the new regularization method was ecient in overcoming the ill-posedness of the inverse heat conduction problem and improving the stability and accuracy of the solutions. KEY WORDS Orthogonal experimental design; Regularization method; Parameters identication; Numerical simulation

1 Introduction The numerical simulation technology is being an important tool in designing and optimizing the casting process. The accurate material physical properties, as well as the initial and boundary conditions, are essential to the simulation. However, lacking of accurate parameters is one of challenges. The inverse heat conduction method is one of methods to identify the above-mentioned parameters based on the temperature measurement data. One of the earliest inverse methods was proposed by Stolz in 1960 to solve a quenching problem involving a spherical geometry[1,2] . Beck et al.[3] then introduced methods incorporating multiple future temperature measurements in 1965. Subsequently, many researchers have used regularization method, dynamic programming, smoothing techniques, Kalman ltering, and conjugate gradient methods to solve the inverse heat conduction problem (IHCP)[413] . The IHCP belongs to the class of ill-posed problems, and its solution is sensitive to the temperature measurement data and it is very dicult to satisfy the stability. A new inverse

Corresponding author. Senior engineer, PhD, Tel.: +86 21 62824255 or +86 13916423049. E-mail address: dasui@sjtu.edu.cn (Dashan SUI) DOI: 10.1016/S1006-7191(08)60065-4

 14 method was presented according to the Tikhonov regularization theory, and one appropriate regularized functional was established to overcome the ill-posedness and improve the accuracy and stability of the solution. The functional was solved by the sensitivity coefcient and Newton-Raphson iteration method. Moreover, orthogonal experimental design was used to estimate the appropriate initial value and variation domain of each variable to decrease the iteration numbers and improve the identication accuracy and eciency. 2 Mathematical Model of the DHCP The Direct Heat Conduction Problem (DHCP) is to solve the temperature eld when all material physical properties, initial, and boundary conditions are completely given. The Fourier heat conduction equation can be solved to nd the transient temperature eld in the casting solidication process. The mathematical model is as follows[14] : cp 2T 2T 2T T = + + t x2 y 2 z 2 +Q (1)

where is density, is thermal conductivity, cp is specic heat capacity, T is temperature, t is time, Q is heat resource. The initial condition is: T (x, y, z, t)|t=0 = T0 where T0 is initial temperature. The third boundary condition is: T n = h(T1 T2 ) (3) (2)

where T1 and T2 is, respectively, the surface temperature of casting and sand mold on the contact location, and h is the interfacial heat transfer coecient (IHTC) of the contact surface between casting and sand mold. Various numerical methods can be used to solve Eq.(1), the nite element method (FEM) was used to solve the transient temperature eld of casting and sand mold in the solidication process on the commercial CAE software platform-ABAQUS in the article. 3 Mathematical Model of the IHCP The process to identify the unknown parameters, such as the material physical properties, the initial and boundary conditions based on the temperature measurement data, is termed the IHCP. A new inverse method was presented according to the Tikhonov regularization theory, and one appropriate regularized functional was established to decrease sensitivity to the temperature measurement data, overcome the ill-posedness, and improve the accuracy and stability of the solution. 3.1 Tikhonov regularization mathematical model The essential principle of the Tikhonov regularization method is to convert the ill-posed problem into a well-posed problem by adding a penalty term to the objective function[15,16] .

 15 The regularized functional was established according to the Tikhonov regularization theory. It writes: J () = 1 Nt Nm 1 m 1 c 2 2 [Tij Tij ()] + N i=1 j =1 T
Nt Nm

1 0 2 2 [k k ] k=1 k

(4)

m represents the measured temperature at a certain time t (i = 1, , N ) and well where Tij i t c () is the corresponding calculated temperature. dened location xj (j = 1, , Nm ). Tij is the unknown variable vector, and ={1 , 2 , , N }, where N is the number m , is a typical of unknown variables. T is the error of the measured temperature, Tij k interval within which each of the variable k is allowed to vary around the initial value 0 k . is the regularization parameter, and >0. The minimum of the functional J () can be deduced to identify the unknown variable . In order to minimize J (), one writes:

1 J = l Nt Nm

(2) 2 0 m c 2 [Tij Tij ()] Xijl + N 2 [l l ] = 0 T k i=1 j 1

Nt Nm

(5)

where Xijl is the sensitivity coecient[17] , it can be expressed approximately as Xijl =

c () c ( , , + , , c Tij Tij 1 N ) Tij (1 , , l , , N ) l l = l l

(6)

where l is a priori perturbation of the variable l . The Newton-Raphson iteration method was used to nd the solution. One writes:
c c Tij ( +1 ) ( ) + = Tij N Xijk k k=1

(7)

where the increments k can be solved using Eq.(5) by Taylor s formula, and keeping only the linearization terms, it is dened by: fl = 1 Nt Nm 1 Nt Nm
Nt Nm

1 m 1 c 0 2 [Tij Tij ( )] Xijl N 2 (l l ) k i=1 j 1 T

Nt Nm

(8)

flk =

Xijk Xijl lk 2 2 = Alk (lk is Kroneker operator) T N k i=1 j =1

N

(9)

Then:

Alk k = fl
k=1

(10)

3.2 Regularization parameter There are two methods to identify the regularization parameter: a-priori method and aposteriori method. The Arcangeli Criterion is one discrepancy method as one of a-posteriori ones to identify the regularization parameter deduced by Arcangeli[16] . It writes: ||A T || = 0 (11)

 16 Then: =
2 ||A T || = 2 T 2 ||A T || Nt Nm i=1 j 1 m c [Tij Tij ()]2

(12)

1 Nt Nm

(13)

The regularization parameter can be deduced: =

1 N t N m 2 T Nt N m i1 j =1 m T c ()]2 [Tij ij

(14)

3.3 Detailed iterative procedure of IHCP The new inverse method can be implemented in a fairly simple way to identify the unknown variables. The iterative procedure is as follows. (1) At the beginning, the components of vector are initiated to some values, and the maximum iteration number is dened. c ( ) of casting and sand mold are calculated by the FEM (2) The temperatures Tij program of DHCP. (3) Each of the variable k is varied by k and the temperatures are again calculated. Using Eq.(6), the sensitivity coecients are deduced. (4) Using Eqs.(8), (9), and (10), the equations are solved to deduce the increment, k . If the maximum relative variation of the variables is smaller than a desired tolerance, k max| k |<, then the iteration calculation will be nished. If not, the k values will be +1 updated, k =k + k , and the calculation proceeds with the next iteration (step 2). It should be noticed that the direct calculations of transient temperature eld must be solved (N +1) times for each of inverse iteration; thus, it will be very large with the number of variables increasing. So the orthogonal experimental design was used to estimate the appropriate initial value and variation domain of each variable to decrease the number of iteration and improve the identication accuracy and eciency. 4 Application of the Inverse Method The inverse analysis was performed to identify the physical properties of sand mold and the IHTC at the meantime for the aluminum alloy sand mold casting in the solidication process to verify the validity of the new inverse method. 4.1 Temperature measurement experiment Casting experiment was designed to measure the temperature at dierent location in the casting and sand mold, and the temperature measurement data were the input data to the IHCP. Three-part molding was used, the casting was aluminum alloy AlSi7Mg, and the sand mold was dry silicate bonded sand. Fig.1 shows the casting process diagram.

 17 The choice of the thermocouple location is very important. The principal factor to dene the location is how to decrease the temperature measurement errors and how easy is to x the thermocouples. Thus, T C 1, T C 2, and T C 3, respectively, dened well the location of three thermocouples. Supposed the O point is the coordinate origin, the three positions coordinates are T C 1(65.0,0.0), T C 2(65.0,60.0) and T C 3(32.0,80.0). The thermocouple is K type, and the measurement data were recorded every 0.225 seconds. The pouring temperature of aluminum alloy was 695.0 C, and the initial temperature of sand mold was 30.0 C. The temperature measurement curves at the three locations are illustrated in Fig.2. T C 1M , T C 2M , and T C 3M , respectively, denotes the measured temperatures. 4.2 Known conditions of numerical simulation (1) Physical properties of casting alloy The physical properties of AlSi7Mg were the known conditions, and the nonlinear feature was considered. The detailed valFig.1 Casting process diagram (unit: mm). ues are listed in Table 1[18] . Solidus temperature of AlSi7Mg is TS =542.0 C, liquidus temperature is TL =613.0 C, latent 1M 600 2M heat is L=430.0 kJ/kg. The solid fraction 3M fS (T ) maintains piecewise linear relation to 400 the temperature T , which is illustrated in Fig.3[18] . 200 (2) Physical properties of sand mold The density of sand mold was constant, =1520.0 kg/m3 . The conductivity and spe0 0 1000 2000 3000 4000 cic heat capacity maintained segments linear relationship with temperature, the mathFig.2 Temperature measurement curves. ematical model was separately expressed in Eqs.(15) and (16), and 0 and cp0 were the unidentied variables.
TC TC TC
Temperature /
o

Time / s

0 0.1876

0.00037 T + 0

(T 527.0 C) (20.0 C < T < 527.0 C) (T = 20.0 C)

(15)

 18
Table 1 Physical properties of AlSi7Mg Temp./ C 100.0 300.0 400.0 500.0 542.0 613.0 /kgm3 2650.0 2560.0 2430.0 /W/(mK) 153.0 157.0 169.0 166.0 68.0 cp /J/(kgK) 900.0 1058.0 1279.0 1168.0

cp0 + 375.18

cp =

c p0

0.74 T + cp0

(T 527.0 C) (20.0 C < T < 527.0 C) (T = 20.0 C)

(16)

(3) Mathematical model of IHTC There are many factors of IHTC, and the principal factor is the gap width between casting and sand mold induced by solidication contract. Moreover, the thermal expansion coecient varied with temperature is the main factor to the gap width, and the thermal expansion coecient of casting is greater 23 orders of magnitude than that of sand mold. So the casting temperature is the most important factor to IHTC. Comprehensively, according to the feature of the thermal expansion coecient of casting alFig.3 Solid fraction vs temperature curves. loy varied with temperature, assuming that IHTC was a piecewise function of the casting surface temperature, then it can be dened by: (T > TL ) hL (T TS ) h= (TS < T TL ) (17) (T T ) (hL hS ) + hS L S hS (T TS )
1.0 0.8
Solid fraction

0.6

0.4

0.2

0.0

540

560

580

600

620

Temperature /

where T is the temperature of the casting surface; hL and hS is the corresponding IHTC to the temperature TL and TS , separately, and they both are the unidentied variables. In addition, as one of boundary conditions, the convective heat transfer coecient between sand mold and atmosphere was set 15.0 W/(m2 K). 4.3 Orthogonal experimental design (OED) There were 4 unidentied variables: 0 , cp0 , hL , and hS . The OED was used to estimate the appropriate initial value and variation domain of each variable. It is very eective to decrease the number of iteration of IHCP and improve the identication accuracy and eciency. The experiments of OED were designed with 4 factors and 3 levels using the L9 (34 ) orthogonal table, and the average temperature dierence at T C 1 and T C 2 was the objective

 19 function of OED, it writes: = T 1 Nt Nm

Nt Nm i=1 j =1 c m |Tij Tij ()|

(18)

m is the measured temperature, T c () is the corresponding calculated temperawhere Tij ij ture, which is solved based on the values of 4 variables listed in Table 2. was expectation value in the OED. Time step was set as t=2.25 s, The minimum of T the calculated time was set as t=4398.75 s, then Nt =1955, Nm =2. The detailed projects and results are listed in Table 2. Fig.4 illustrated the trend curves of dierent level vs dierent factor.

Table 2 Projects and the results of OED Factors No. 1 2 3 4 5 6 7 8 9 K1 K2 K3 1 K 2 K 3 K R A 0 /W/(mK) 1 (0.5) 1 1 2 (0.75) 2 2 3 (1.0) 3 3 191.01 70.04 84.68 63.67 23.35 28.23 40.32 B cp0 /J/(kgK) 1 (400.0) 2 (600.0) 3 (800.0) 1 2 3 1 2 3 139.24 104.05 102.44 46.41 34.68 34.15 12.26 C hL /W/(m2 K) 1 (650.0) 2 (800.0) 3 (1000.0) 2 3 1 3 1 2 133.11 151.62 61 44.37 50.54 20.33 30.21 D hS /W/(m2 K) 1 (400.0) 2 (500.0) 3 (600.0) 3 1 2 2 3 1 152.49 86.82 106.42 50.83 28.94 35.47 21.89 / C T 90.04 62.59 38.38 40.53 13.95 15.56 8.67 27.51 48.50

It can be deduced from the range value R in Table 2: RA >RC >RD >RB . It meant that the conductivity of sand mold had the greatest eect on the temperature eld, then followed by hL and hS , but the specic heat capacity had the less eect. The appropriate initial value and variation domain can be estimated by analyzing Table 2 and Fig.4 comprehensively. The initial value of conductivity was =0.75 W/(mK) and variation domain was 0.25 W/(mK); similarly, cp =800.0 J/(kgK) and 2 200.0 J/(kgK); hL =1000.0 W/(m K) and 200.0 W/(m2 K); hS =500.0 W/(m2 K) and 100.0 W/(m2 K).

60

T /

C
40 20

0.500.751.00 A

400 600 800 B

650 800 950 950 C

400 500 600

Fig.4 Trend curves of dierent level vs dierent factor.

 20 5 Identication Results and Discussion The 4 variables, 0 , cp0 , hL , and hS can be identied at the meantime based on the appropriate initial value and variation domain using the foregoing new inverse method. Because the temperature in the casting has minimum sensitivity to the location variation, and the temperature in the sand mold has maximum sensitivity to the location variation, only the temperature measurement data of T C 1 and T C 2 in the casting were employed to identify the variables as the input data. It was considered comprehensively for the thermocouple measurement error and was set T =15.0 C. The time step of direct calculation was t=2.25 s, the calculated time was t=4398.75 s, then Nt =1955, Nm =2. The detailed identication results were: =0.68 W/(mK), cp =817.21 J/(kgK), hL =954.74 W/(m2 K) and hS =411.20 W/(m2 K). The transient temperature eld in the casting and sand mold can be solved by 1 600 using the identication results and known 2 conditions, then the calculated temperature 3 eld at T C 1, T C 2 and T C 3 were obtained. 400 Fig.5 illustrates the calculated temperature of T C 1, T C 2 and T C 3 as T C 1C , T C 2C and 200 T C 3C , respectively. Moreover, the corresponding average temperature dierence at 0 =4.12 C, it T C 1 and T C was solved as T 0 1000 2000 3000 4000 was the optimum compared with the 9 results in Table 2. Fig.5 Calculated temperature curves. The deection value between the cal16 culated temperature and the corresponding measurement one at each location was de1 ned by: 8 c m Tij = Tij Tij (19)
TC C TC C TC C

Temperature /

Time / s

0 c is the calculated temperature, T m where Tij ij is the corresponding measured temperature. 2 -8 Fig.6 illustrated the temperature deec3 tion curves. Upon a comprehensive analysis, the temperature deection curves of T C 1 -16 0 1000 2000 3000 4000 5000 and T C 2 were basically identical with each other, but they dier from T C 3. The variFig.6 Temperature deection curves. ation range of temperature deection was 10.1 C10.1 C at T C 1, 10.0 C9.1 C at T C 2, 15.6 C6.5 C at T C 3. The temperature eld numerical simulation indicated that the error, that is induced by the location variation, was the main factor to the thermocouple in the casting, but the error, that is induced by damping eect and lagging eect, was the main factor to the thermocouple in the sand mold. Especially, the thermal resistance of sand mold was bigger than that of casting, which deduced the damping and lagging eect of the thermocouple worse and the temperature measurement error larger. Comprehensively, it can be concluded that the identication solutions satised the stability according to the temperature variation range.
TC TC Time / s

Temperature /

TC

 21 6 Conclusions (1) The IHCP belongs to the class of ill-posed problem. It presented a new inverse method according to the Tikhonov regularization theory, and one appropriate regularized functional was established to overcome ill-posedness and to improve the accuracy and stability of the solution. The functional was solved by the sensitivity coecient and Newton-Raphson iteration method. (2) The direct calculations of transient temperature eld must be solved (N + 1) times for each of inverse iteration; thus, it will be very large with the number of variables increasing correspondingly. The orthogonal experimental design was used to estimate the appropriate initial values and variation domain of each variable to decrease the number of iterations and improve the identication accuracy and eciency. (3) The temperature measurement experiment was designed to AlSi7Mg sand mold casting. The physical properties of sand mold and IHTC were identied at the meantime using the orthogonal experimental design and Tikhonov regularization method. The results indicated that the new regularization method was ecient in overcoming the ill-posedness and ensuring the accuracy and stability of the solutions.
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