Thermal fatigue analysis of Saffil reinforced aluminium alloys using pressure die casting process

ABSTRACT There are several constituents which causes die fractures in die casting process. Several features can be managed to a certain level by the help of specialists like geometry experts, production specialists and engineers. In die casting procedure main loading feature is fluctuating nature of thermal condition therefore effect of further forces 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 manufacturing period. Failure of die can be recognised when there is fracture line appears on die surface and it grows during further manufacturing. The main objective of this work to find out thermal fatigue analysis of Saffil reinforced Aluminium Alloy (96%Al2O3 and 4% SiO2) dies during pressure die casting procedure. The location of cooling channels from base is varying (0.5 mm–5 mm). Thus six geometry models occurred for every material. Using ANSYS workbench 17.1 to find three major factors related to this analysis work temperature distribution, fatigue life and normal stresses generated in dies.

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