Title: Influence of flow rate on the temperature and pressure conditions during die filling

Authors: M. Zupancic, J. Grum, M. Stekar, V. Bratus

Addresses: Faculty of Mechanical Engineering, University of Ljubljana, Askerceva 6, 1000 Ljubljana, Slovenia. ' Faculty of Mechanical Engineering, University of Ljubljana, Askerceva 6, 1000 Ljubljana, Slovenia. ' Rotomatika d.o.o., Spodnja Kanomlja 23, 5281 Spodnja Idrija, Slovenia. ' Rotomatika d.o.o., Spodnja Kanomlja 23, 5281 Spodnja Idrija, Slovenia

Abstract: Operating conditions of tools for die casting of aluminium alloys are very exacting. Damages to and defects of tools occur at different locations, above all at the die, which is in a direct contact with the melt or a casting. Any incorrectness in the design and manufacture of a tool, especially in its heat treatment, may essentially accelerate the occurrence of damages. Thermo-mechanical stresses in tools produce fatigue microcracks, which will, along with tool operation, propagate into depth and in width. After a certain time, these damages may result in visible damages to the casting or even in a fatigue failure of the tool or local damages to the die. Numerical simulations using the method of finite elements and simultaneous experimental measurements were performed in order to minimise the occurrence of premature undesired damages and locate hot spots at the tool. Simulations applied to a tool made of material 1.2343 were performed at one of aluminium-alloy products – Support carrier – produced by a company Hidria Rotomatika d.o.o.

Keywords: die casting tools; dies; thermo-mechanical stress; finite element method; FEM; temperature; pressure; flow rate; aluminium alloys; tool damage; tool failure; simulation.

DOI: 10.1504/IJMMP.2009.031593

International Journal of Microstructure and Materials Properties, 2009 Vol.4 No.5/6, pp.594 - 604

Published online: 12 Feb 2010 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article