Numerical Simulation Of Temperatures Field And Thermal Stresses Field Of The Die For Producing Aluminum Alloy Wheel Hub In Die Casting Process

Finite element analysis (FEA) simulation of filling process, the temperature fields and stress fields in the die casting process greatly promotes the development of the die casting process,and plays an important role in the optimizing technical designing,improving the casting quality,avoiding hot crack faults and decreasing residual stress.In this thesis, the development of numerical simulation of die casting process, and prospect the developing trend in the future have been summarized at first. An elastic-plastic 3D FEA model of the transient temperature field and thermal-stress field has been theoretically built. And a mathematical model of the initial condition, boundary condition, and latent heat disposal is built as well. Simulations and analysis of the temperature fields and thermal stress fields of a typical die adopted in die casting process are described.Based on the FEA software—PROCAST ,the temperature field in die casting process has been simulated,According to the result of temperature field,we can know that the Temperature difference in the rung join reached to 45℃,and temperature gradient in the rung join has reached to 13℃/mm.Take a step forward,we proved that the thermal stress is very high in the high temperature gradient zone. We selected a typical cross-section which exhibits high thermal stress in this regional,to analysis the lifetime of the die. We selected two points on C cross-section too,.Then we has mapped out the thermal stress curve in A and B points.We set a lifetime estimation model,According to the simulation results and the life estimation model,we predicted the life span of aluminum die-casting die with different Pouring temperature about 650°C, 670°C, 690°C, the case of C-section A point in X direction of maximum strain were: 0.0221 mm, 0.023mm, 0.0242mm. And forecasts in the three different temperatures Die Casting life are as follows: 105000,100000,91000 shots. We pointed out that suitable aluminum alloy pouring temperature is 650℃.I In this thesis, The results of simulations of aluminum alloy wheels Die casting temperature field will play an important role in guiding improving the casting process parameters. Thermal stress in numerical analysis can be used in forecasting the life of mold and arrangements for the production of enterprises.