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There are several constituents that cause die fractures in the die casting process. Several features can be managed to a certain level with the help of specialists like geometry experts, production specialists and engineers. In the die casting procedure, the main loading feature is the fluctuating nature of thermal conditions; therefore, the effect of further forces is comparatively negligible. In order to achieve cost-efficient manufacturing for die casting, different metals' essentiality of die’s high operational life is required. Expenditure on die substitution is very high and it increases the manufacturing period. Failure of die can be recognised when fracture line appears on the die surface and it grows during further manufacturing. The main objective of this work is to find out thermal fatigue analysis of aluminium alloy (A02240) dies during the pressure die casting procedure. The location of cooling channels from base is varying (0.5–5 mm). Thus, we get six geometry models for every material. By using ANSYS workbench 17.1, we find three major factors related to this analysis: work temperature distribution, fatigue life and normal stresses generated in dies.

advances in materials and processing technologies

Effect of die geometry on thermal fatigue analysis of aluminium alloy (A02240) dies of low melting point alloys casting using pressure die casting process