Modeling the Mechanical Performance of Die Casting Dies
The majority of die casting computer modeling work focuses on thermal or filling issues including solidification. Although the simulation of mechanical and thermal load effects is critical for high pressure die casting and for squeeze casting it is not yet addressed by commercial casting design packages. In an attempt to resolve this, stress analysis packages for the casting are beginning to be used. But they are based on the nominal part geometry (as defined by the CAD model) and not the actual part shape at ejection. This is not a reasonable assumption for die casting. Due to the clamping and operating pressure involved, the mechanical performance of the die and machine must be considered in order to better understand the part ejection conditions.
As a direct extension of an existing projects “Die Deflection Modeling: Empirical Validation and Technology Transfer”, researchers from Ohio State University will further advance the state of the art in computer modeling and simulation to solve die casting design problems in practical ways. Key relationships among the design variables will be determined, and a design methodology will be established. This work will lead to a better understanding of how to design dies to meet clamping, thermal, and pressure loads.