In die casting design, residual stress and thermal deformation based FEM analysis are gaining enormous importance. Shiga et al. have reported that the thermal and residual stress of the I-shaped model could be more accurately predicted by using the elastoplastic-creep model than by using the conventional elasto-plastic model. In this study, factors affecting the contact forces between the die and the casting were analyzed by using a little more complicated model than the I-shaped model. The results clearly indicate that, irrespective of shapes, the plastic strain term affects the contact forces the most, and that the creep term further reduces the contact forces. Furthermore, a comparison between the simulated and measured values of the residual stress of an aluminum die-cast product confirms the superiority of the elasto-plastic-creep model than the elasto-plastic model in predicting the residual stress, which could also be used instead of the contact forces.
In the die design of high pressure die casting (HPDC), in order to prevent the casting from the warpage, it is essential to predict ejection force of each ejector pin before locating it. Recently, Shiga et al. revealed that their developed elasto-plastic-creep model is more accurate than conventional elasto-plastic models to estimate the thermal stress of casting during cooling with constraint of dies.In this study, by using the elasto-plastic-creep model, thermal stress analysis was conducted to predict the force generated on each ejector pin in the HPDC process. As a result, the force was estimated within the error of 30% in respect to the measured value. It was also predicted that increasing in the curing time increases the force.
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