Effects of Die Design & Dimensional Features on Thermal Fatigue Cracking of Die Casting Dies
The objective of the project is to identify and evaluate the effect of design factors such as size and location of cooling lines, sudden changes in cross-section, and sharp radii on the life of die casting dies. The study will provide die designers with computer tools that allow them to predict the thermal stresses in dies, and a method to relate these stresses with thermal fatigue cracking. These tools can be applied towards mitigating or eliminating design related problems and their adverse effect on die life.
The study will develop a new approach in design of dies for thermal fatigue resistance. This approach is designed to identify potential hot spots (thermal) and high stresses in the design by minimizing them by modifying the dimensions of the inserts and the location and size of the cooling lines. It includes 1) computer aided design of the die with all geometrical details, including location of cooling lines, 2) couple finite element modeling of flow/thermal/stress of the die, and 3) thermal fatigue immersion testing to determine the actual effect of the maximum design temperatures and stresses on the heat checking damage.