Thermal fatigue failure behavior of die-casting insert

doi:10.13251/j.issn.0254-6051.2022.02.044

Abstract

Abstract: Failure mechanism of the thermal fatigue failed die-casting insert used for 1200 times was analyzed, and thermo-mechanical coupled numerical analysis model of die-casting process was established. The evolution of temperature and stress field of the die-casting insert during working was studied, and its service life was predicted. The results show that the failure of the insert is due to the thermal fatigue behavior caused by the erosion of high temperature molten aluminum liquid and the rapid cooling of the coolant during the die casting process. During the cyclic die-casting, the stress concentration occurs at the corner of the bulge of the insert, and the maximum equivalent stress is about 788 MPa, where the thermal fatigue crack initiates and propagates. The low cycle fatigue life prediction law is used to predict the thermal fatigue life of the insert, and the result is about 1651 times, which is in agreement with the actual life. The thermo-mechanical coupled numerical model in this paper can provide a reference for the reliability design of the die-casting insert.

Key words: hot work die steel, die-casting insert, thermal fatigue, life prediction, numerical simulation

CLC Number:

TG142.1

Cai Xianjie, Wu Boya, Zuo Pengpeng, Li Junwan, Guo Wei. Thermal fatigue failure behavior of die-casting insert[J]. Heat Treatment of Metals, 2022, 47(2): 250-256.

References

[1]陈蕴博. 热作模具钢的选择与应用[M]. 北京: 国防工业出版社, 1993: 40-42.
Chen Yunbo. Choice and Application of Hot Die Steels[M]. Beijing: National Defense Industry Press, 1993: 40-42.
[2]Yeh Shu-Hung, Chiu Liu-Ho, Pan Yeong-Tsuen, et al. Relative dimensional change evaluation of vacuum heat-treated JIS SKD61 hot-work tool steels[J]. Journal of Materials Engineering and Performance, 2014, 26(3): 2075-2082.
[3]Chen C R, Wang Y, Ou H G. Energy-based approach to thermal fatigue life of tool steels for die casting die[J]. International Journal of Fatigue, 2016, 92: 166-178.
[4]赵建伟. 铝合金压铸模具龟裂失效分析[J]. 中国金属通报, 2020(1): 96, 98.
Zhao Jianwei. Analysis of cracking failure of aluminum alloy die casting die[J]. China Metal Bulletin, 2020(1): 96, 98.
[5]谭成, 马党参, 王华昆, 等. H13钢压铸模具的失效分析[J]. 机械工程材料, 2016, 40(1): 106-110.
Tan Cheng, Ma Dangshen, Wang Huakun, et al. Failure analysis of a die casting die made of H13 steel[J]. Materials for Mechanical Engineering, 2016, 40(1): 106-110.
[6]Salem M, Le R S, Dour G, et al. Effect of aluminizing and oxidation on the thermal fatigue damage of hot work tool steels for high pressure die casting applications[J]. International Journal of Fatigue, 2019, 119: 126-138.
[7]李超婧. 提高新型高Cr热作模具钢焊缝热疲劳性能的研究[D]. 长春: 吉林大学, 2009.
[8]康进武, 游锐, 聂刚, 等. 铝合金压铸模具热疲劳寿命试验研究[J]. 机械工程学报, 2012, 48(12): 63-68.
Kang Jinwu, You Rui, Nie Gang, et al. Study on the thermal fatigue life of H13 steel for aluminum alloy casting[J]. Journal of Mechanical Engineering, 2012, 48(12): 63-68.
[9]苏楠, 陈明和. 热作模具热疲劳寿命评估及预测方法的研究进展[J]. 中国机械工程, 2019, 30(11): 1378-1385.
Su Nan, Chen Minghe. Research advances in evaluation and prediction method of thermal fatigue life for hot-working dies[J]. China Mechanical Engineering, 2019, 30(11): 1378-1385.
[10]周路海, 张洪波, 黎军顽, 等. H13热作模具钢感应加热循环过程的数值模拟[J]. 材料热处理学报, 2016, 37(2): 227-234.
Zhou Luhai, Zhang Hongbo, Li Junwan, et al. Numerical simulation on induction heating cycle process of H13 hot-work die steel[J]. Transactions of Materials and Heat Treatment, 2016, 37(2): 227-234.
[11]Qayyum Faisal, Kamran Atif, Ali Asghar, et al. 3D numerical simulation of thermal fatigue damage in wedge specimen of AISI H13 tool steel[J]. Engineering Fracture Mechanics, 2017, 180: 240-253.
[12]Tunthawiroon Phacharaphon, Li Yunping, Koizumi Yuichiro, et al. Strain-controlled iso-thermal fatigue behavior of Co-29Cr-6Mo used for tooling materials in Al die casting[J]. Materials Science and Engineering A, 2017, 703: 27-36.
[13]Lu Yan, Ripplinger Keith, Huang Xuejun, et al. A new fatigue life model for thermally induced cracking in H13 steel dies for die casting[J]. Journal of Materials Processing Technology, 2019, 271: 444-454.
[14]Guo Can, Yu Dunji, Sun Xingyue, et al. Fatigue failure mechanism and life prediction of a cast duplex stainless steel after thermal aging[J]. International Journal of Fatigue, 2021, 146: 106161.
[15]Şimşir C, Gür C H. A FEM based framework for simulation of thermal treatments: Application to steel quenching[J]. Computational Materials Science, 2008, 44(2): 588-600.
[16]张静, 张松, 李斌训. 基于逆向拟合法的H13钢J-C本构修正模型[J]. 中南大学学报(自然科学版), 2019, 50(8): 1808-1815.
Zhang Jing, Zhang Song, Li Binxun. Modified J-C constitutive model of H13 steel based on reverse fitting algorithm[J]. Journal of Central South University(Science and Technology), 2019, 50(8): 1808-1815.
[17]左鹏鹏. 压铸模具钢热机械疲劳行为及损伤机理研究[D]. 上海: 上海大学, 2018.
[18]朱汝城, 李杨德, 王成勇, 等. 咖啡机顶盖铝合金压铸模具的热疲劳分析[J]. 特种铸造及有色合金, 2010, 30(5): 424-426, 386.
Zhu Rucheng, Li Yangde, Wang Chengyong, et al. Thermal fatigue analysis of aluminum alloy die casting die for dome of coffee machine[J]. Special Casting and Nonferrous Alloys, 2010, 30(5): 424-426, 386.
[19]王要利, 宋克兴, 张彦敏. 热作模具钢热疲劳行为的研究现状[J]. 材料热处理学报, 2018, 39(4): 1-13.
Wang Yaoli, Song Kexing, Zhang Yanmin. A review on thermal fatigue behavior of hot working die steel[J]. Transactions of Materials and Heat Treatment, 2018, 39(4): 1-13.
[20]张涵宇. 某型高镍铸铁排气歧管热疲劳寿命预测与结构改进[D]. 广州: 华南理工大学, 2017.
[21]孙永明, 陈振宇, 陈国恩, 等. 利用热应力场模拟估算压铸模具局部区域寿命[J]. 特种铸造及有色合金, 2020, 40(6): 632-635.
Sun Yongming, Chen Zhenyu, Chen Guo'en, et al. Simulation analysis of thermal stress field used to estimate the local life of die-casting dies[J]. Special Casting and Nonferrous Alloys, 2020, 40(6): 632-635.