Evaluating Die Life in High-Pressure Die Casting: Correlating Temperature Dynamics and Durability through Altair Inspire Cast and SIMSOLIDPages 377-392
Sourav Das Abstract:
This paper explores the efficiency of high-pressure die casting (HPDC) in producing complex geometries while focusing on fatigue patterns and failure points in dies subjected to repeated thermal stress. An energy-based semi-empirical model is proposed to predict fatigue life, integrating mean stress, stress amplitudes, and strain through finite element analysis (FEA). The study includes experimental characterization of die temperature profiles during HPDC, along with statistical correlation studies that connect temperature dynamics to durability metrics. Numerical simulations using Altair's Inspire Cast and SIMSOLID analyze the die's thermal behavior and predict temperature distributions, providing valuable insights into the conditions leading to fatigue failure. Additionally, a fatigue analysis of an AISI H11 tool steel component is presented, revealing a clear relationship between the number of cycles and the accumulation of fatigue damage, highlighting the importance of thorough evaluations in the design process to enhance reliability and performance. Overall, this research aims to contribute to improved understanding and optimization of die life in HPDC applications, ultimately ensuring the safety and efficiency of manufactured components.
Keywords: HPDC,
Fatigue damage,
Fatigue life,
SIMSOLID,
Inspire cast,
Manufacturing,
Temperature mapping,
EN-time
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