Casting dimensional control and fatigue life prediction for permanent mold casting dies. Technical report, September 29, 1993--May 31, 1997
Efforts as part of a three year program to address metal casting dimensional control and fatigue life prediction for permanent mold casting dies are described. Procedures have been developed and implemented to collect dimensional variability data from production steel casting. The influence of process variation and casting geometry variables on dimensional tolerances have been investigated. Also efforts leading to the developments and validation of a CAD/CAE model to predict the thermal fatigue life of permanent molds for aluminum castings are described. An appropriate thermomechanical property database for metal, mold and coating materials has been constructed. A finite element model has been developed to simulate the mold temperature distribution during repeated casting cycles. Validation trials using a permanent mold casting machine have indicated the success of the temperature distribution model developed. A combination of experimental and modeling techniques have been employed to extend their knowledge of permanent mold casting. The influence of coatings on casting solidification and mold temperatures has been determined. The computer model has been extended to predict thermally induced stresses and strains in the mold and to predict the number of cycles required to crack the mold. Experimental results have been used to validate the extended model.
- Research Organization:
- Pennsylvania State Univ., University Park, PA (United States)
- Sponsoring Organization:
- USDOE Assistant Secretary for Energy Efficiency and Renewable Energy, Washington, DC (United States)
- DOE Contract Number:
- FC07-93ID13235
- OSTI ID:
- 548723
- Report Number(s):
- DOE/ID/13235-T1; ON: DE98001225; TRN: AHC29724%%126
- Resource Relation:
- Other Information: PBD: 1 Jun 1997
- Country of Publication:
- United States
- Language:
- English
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