Abstract
Die casting is forcing molten metal into a mould with high pressure. Die casting has two dies namely moving die and fixed die where the moving one will move over the fixed die. Die casting is majorly used for high-volume production. This paper focused on the physical phenomenon of die casting for two dies (moving die and fixed die) using two different alloy materials with variable material chemical compositions. The numerical analysis is carried out for the die casting process to determine the crack formation zone by temperature distribution and structural analysis by stress-strain relationship. The numerical analysis is carried out for both the dies. The fixed die is analyzed with an H13 tool steel material with two moving die materials as aluminum alloy (A356) and magnesium alloy (AZ91D). Both the dies (fixed and moving) were designed by using design software and meshing is carried out followed by analysis using the analysis software. The physical parameter for the dies is applied that is temperature distribution is carried out by applying a temperature of 850 °C and 650 °C over the fixed die for aluminum and magnesium alloy, respectively. Structural analysis is carried out for the moving die with a load of 1,000 N for both aluminum and magnesium alloys with 1000 number of iterations. The results from the numerical analysis are derived and analyzed for both temperature distribution and structural analysis. The crack formation zone is found out by means of temperature gradient and the stress-strain relationship is found out by means of structural analysis. From the results, it was concluded that the crack zone is obtained at 1.22E-10 °C/mm and 6.856E-14 °C/mm of thermal gradient and structural analysis in terms of maximum stress of 446.94 MPa and 448.52 MPa for aluminum and magnesium alloys, respectively.
Highlights
Molten metals are formed with the application of high pressure into a mould cavity, in which the mould cavity is fabricated by two hardened tool steel dies, by the process of machining, the mould cavity is shaped depending on the application
The crack zone for the aluminum alloybased fixed die is found at the range of 1.22E-10 °C/mm thermal gradient and for magnesium alloy is at the range of 6.856E-14 °C/mm thermal gradient
The moving die of aluminum alloy and magnesium alloy has a maximum stress of 446.94 MPa and 448.52 MPa with a linear relationship in strain of 6.324e-3 mm/mm and 1.0013e-2 mm/mm
Summary
Molten metals are formed with the application of high pressure into a mould cavity, in which the mould cavity is fabricated by two hardened tool steel dies, by the process of machining, the mould cavity is shaped depending on the application. Non-ferrous metals are used for die-casting and depends upon the type of metal being used, a machine such as hot or cold chamber is used. AISI H13 and AISI H11 are used to find out the resistance capacity towards thermal fatigue over the surface layer, which the surface is cladded by GTA welding. Thermal fatigue resistance is experimented by the continuous cycle of heating and cooling in the bath of aluminum alloy 226 and water-based lubricant, respectively. The results indicate that fatigue resistance of maraging steel weld is lower than the AISI H11 tools [1]. The mass of automotive can be decreased by using magnesium-based die casting because magnesium die casting has the advantage of near net shape forming, light weight, optimized strength to weight ratio, consolidation of part and additional components integration [2]
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