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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2012

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Approach to the prediction of thermal fatigue of aluminium high pressure die casting (AlSI H13) using the Basquin equation and finite elements

Concer D., Woellner N., Marcondes P. V. P.

Journal of Achievements in Materials and Manufacturing Engineering

2012

Vol. 55, nr 2

439--445

Purpose: The main aim of the present study was to analyze the influence of the thermal fatigue on the AISI H13 die surface during the aluminium high pressure die casting process. Design/methodology/approach: Two different gradients of temperature were considered (ΔT = 200 and 250°C). The thermal stresses were obtained through computer numerical analysis - Finite Element Method. Then an analytical study, through the equation of Basquin, was conducted to determine the number of cycles until the die failure. Findings: Taking in account the divergences found in the solutions for determining the number of life cycles to die failure and guided by technical data and commercial experience of life cycles for the AISI H13 steel it was possible to propose coefficients of correction for the equation of Basquin. Research limitations/implications: It should be highlighted that the use of the proposed corrected coefficients for the Basquin equation can show a satisfactory results related to the practice - valid only for similar conditions of this work. Practical implications: The behavior of the steel used for the dies are dependent of the temperature and density, elastic modulus, Poisson’s ratio, coefficient of thermal expansion, hardness, thermal conductivity and yield strength and an incorrect steel selection can lead to thermal stresses amplitude favorable for the onset of the cracks. Originality/value: The dies play an important role in the aluminium high pressure die casting process. During the die manufacturing process the die design and the steels behavior are a major concern on efficient manufacturing, i.e. related to maximize the life cycle. During the injection process the thermal fatigue is one of the responsible factor of onset of cracks - estimated to be approximately 80%.