Abstract: This paper is to find the influence of thermal stresses on die casting design. Finite Element Analysis (FEA) have been utilized for this purpose. Different parameters such as temperature, and mechanical properties of die material are studied. Temperature transients at different locations of the specimens are measured and used in calibration of finite element model (FEM). The computation of transient stresses is performed by developed FEM. The results showed significant differences in produced thermal stresses for analyzed materials, test parameters, and edge geometries.

Abstract: Die ca sting process is one of the widely used processes in the manufacturing area. It has the capability for high production rate s with good strength, high quality part s with complex shape s. Die is the main factor which affect s the cost of this process. Even when the process is semi or fully automated the cost of the die is proportionately high. Commercially available FEA Software (LUSAS) has been u sed. A full Finite Element Analysis was carried out in order to achieve an optimum de sign, and to predict the die life. The analysis has been repeated several time s for different element s to achieve the best possible de sign. Since ca sting is a repetitive manufacturing process, fatigue load was taken into consideration and analysis carried out for a high number of cycle s.