Effect of Die Geometry on Fatigue Analysis of Aluminium Alloy (ADC12 Aluminium A383) using Pressure Die Casting Process

Authors

  • Poshan Dewangan  Research Scholar, RSR Rungta College of Engineering and Technology, Bhilai, Chhattisgarh, India
  • VedPrakash Dewangan  Research Scholar, RSR Rungta College of Engineering and Technology, Bhilai, Chhattisgarh, India
  • Vinay Kumar  Research Scholar, RSR Rungta College of Engineering and Technology, Bhilai, Chhattisgarh, India
  • Rakhi Rajnal  Research Scholar, RSR Rungta College of Engineering and Technology, Bhilai, Chhattisgarh, India
  • Lokesh Singh  Assistant Professor, RSR Rungta College of Engineering and Technology, Bhilai, Chhattisgarh, India

Keywords:

Aluminium Alloys, Die-Casting, Fatigue, Life, Normal Stress

Abstract

Dies for aluminium alloys die-casting fail because of a great number of different and simultaneously operating factors. Some of them may be controlled to some extent by the die-casting experts. In the process of the die-casting the primary source of loading is cyclic variation of the temperature; the influence of other loads is relatively insignificant. For economical production of aluminium and aluminium alloys die castings it is important that the dies have a long working life. The replacement of a die is expensive in both: money and production time. The main objective of this work to find out The fatigue of die casting Aluminium Alloy (ADC12 ALUMINIUM A383) causes reduction in tool life and seriously affects the surface conditions such as microstructure, hardness, surface finish and residual stresses. The size and location of cooling channels relative to the surface of the die, which affect the fatigue life of dies. This work focus on the fatigue analysis of Aluminium alloy pressure die casting process and analyses the effect of coolant channel location on fatigue parameters such as life, damage, equivalent alternating stress and biaxiality using ANSYS Workbench 17.1 finite-element package.

References

  1. J. Collot et al. Review of New Process Technologies in the Aluminum Die-Casting Industry. Materials and Manufacturing Processes, 2001. 16(5): p.595-617.
  2. Q. Han, and S. Viswanathan, Analysis of the mechanism of die soldering in aluminium die casting. Metallurgical and Materials ransactions, 2003.34(1): p.139-146.
  3. A. Srivastava, V. Joshi and R .Shivpuri; 2004; Computer modelling and prediction of fatigue cracking in diecasting tooling. Int. J. Wear 256: 38-43.
  4. D. Schwam, J. F. Wallace and S. Birceanu; 2004; Effect of design factors on fatigue cracking of die casting dies. DE-FC07-00ID138486,US Department of Energy, Washington, DC.
  5. D. Novovic, R. C. Dewes and D. K. Aspinwall;2004; The effect of machined topography and integrity on fatigue life. Int. J. Mach Tools Manuf. 44 :125-134.
  6. M. Okayasu; 2009; Comparison of mechanical properties of die cast aluminium alloys: cold vs. hot chamber die casting and high vs. low speed filling die casting. Int. J. Cast Met. Res. 22: 324-381.
  7. S. Aqida et. al., Fatigue properties of laser treated steels. International Journal of Material Forming, 2010. 3(1): p.797-800.
  8. J.J.Moverare,; D. Gustafsson. Hold-time effect on the thermo-mechanical fatigue crack growth behaviour of inconel 718. Mater.Sci. Eng. A 2011, 528, 8660–8670.
  9. S. Chang, K.Huang, and Y. Wang, Effects of thermal erosion and wear resistance on AISI H13 tool steel by various surface treatments. Materials Transactions, 2012.53(4): p.745-751.
  10. D. Klob?car.; L. Kosec; J.Tušek; Thermo fatigue cracking of die casting dies. Eng. Fail.Anal. 2012, 20, 43–53.
  11. I. Koutiri, , et al., High cycle fatigue damage mechanisms in cast aluminium subject to complex loads. International Journal of Fatigue, 2013. 47: p. 44-57.
  12. D. Matiskova,.; S. Gaspar,.; L. Mura,. Thermal factors of die casting and their impact on the service life of moulds and the quality of castings.ActaPolytech. Hung. 2013, 10, 65–78.
  13. D. Matiskova,.; S. Gaspar,.; L. Mura,. Thermal factors of die casting and their impact on the service life of moulds and the quality of castings.ActaPolytech. Hung. 2013, 10, 65–78.
  14. FazlianaFauzun, S. N. Aqida, S. Naher and D. Brabazon;2014; effects of fatigue on laser modified H13 Die Steel; Journal of mechanical engineering and sciences(JMES);ISSN:2289-4659; volume 6, pp. 975-980.
  15. Xu, W.; Li, W.; Wang, Y. Experimental and theoretical analysis of wear mechanism in hot-forging die and optimal design of die geometry. Wear 2014, 318, 78–88.
  16. Qian wan, Haidong Zhao and Chun Zou; 2014; effect of micro porosities on fatigue behavior in Aluminium die casting by 3D x-ray tomography inspection; doi.org/10.2355/isijinternatinal.
  17. O. Ammar,; N. Haddar,; L. Remy, Numerical computation of crack growth of low cycle fatigue in the 304l austenitic stainless steel. Eng. Fract. Mech. 2014, 120, 67–81.
  18. I. Vicario, J. K. Idoiaga, E. Arratibel and P. Caballero;2015; Development of HPDC advanced dies by casting with reinforced tool steels; International Journal of manufacturing Engineering;doi.org/10.1155/2015/287986.
  19. C. Chen; Y. Wang; Energy-based approach to fatigue life of tool steels for die casting dies. Int. J. Fatigue 2016, 92, 166–178.
  20. Xu Li, Bao-sheng Liu, Li-fengHou and Ying-hui Wei;2017; Failure investigation of an AlSi9Cu3 Alloy Die-Cast Cavity Insert; Journal of failure analysis and prevention; issue6.
  21. Ibrahim Ozbay, Tamer Aydiner, GurkanYilmazoglu and Hafize Celik;2019; Aluminium high pressure Die casting application on rear frame rails; European mechanical science; e-ISSN: 2587-1110.
  22. Federico Simone Gobber, Andrea Giuseppe Pisa and Mario Rosso;2019; design of a Test Rig for the characterization of fatigue and soldering resistance of the surfaces of tool steels for high pressure die casting dies; Steel research International: doi.org/10.1002/srin.201900480.

IInternational Journal of Scientific Research in Mechanical and Materials Engineering

Downloads

Published

2021-05-30

Issue

Volume 5, Issue 3, May-June-2021

Section

Research Articles

License

Copyright (c) IJSRMME

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

How to Cite

[1]
Poshan Dewangan, VedPrakash Dewangan, Vinay Kumar, Rakhi Rajnal, Lokesh Singh, " Effect of Die Geometry on Fatigue Analysis of Aluminium Alloy (ADC12 Aluminium A383) using Pressure Die Casting Process, IInternational Journal of Scientific Research in Mechanical and Materials Engineering(IJSRMME), ISSN : 2456-3307, Volume 5, Issue 3, pp.10-16, May-June-2021.