Amirkabir University of Technology Amirkabir Journal of Mechanical Engineering 2008-6032 53 Issue 4 (Special Issue) 2021 06 22 Thermal stress analysis for an aluminum die cast die Thermal stress analysis for an aluminum die cast die 2687 2702 4146 10.22060/mej.2020.18049.6723 FA HamidReza Khayyati Deparment of mechanical engineering, Hakim Sabzevari University, Sabzevar, Iran Yadollah Alinia Deparment of mechanical engineering, Hakim Sabzevari University, Sabzevar, Iran 0000-0001-8475-7382 Journal Article 2020 03 05 In this study, the thermo-elastic behavior of an aluminum die cast die during the casting process is analyzed. The cyclic symmetry nature of the die geometry offers a simplified reduced model for the finite element simulation. It is assumed that the temperature distribution on the molten metal affected boundaries follows a smooth function variation while the free surfaces of the die experience a convection heat transfer type. Considering a particular boundary condition, the results of the current study conform to the available analytical solutions. A detailed sensitivity analysis is conducted to highlight the effects of die preheat, groove corner radius of curvature and the thermal barrier coatings. The results indicate that the die preheating before the casting process can significantly decrease the stress level within the system. Also, an increase in the radius of curvature for the groove corners may result in a 25% reduction of the von Mises stress around these crack susceptible zones. Application of hard chromium or a silicon nitride thermal barrier coating considerably increases the thermal shock strength of the die such that a 0.1mm thick hard chromium coating can decrease the maximum von Mises stress about 49% with respect to the non-coated specimen. Especially for a functionally graded coating type, the reduction in maximum von Mises stress is around 70% compared to the non-coated specimen. In this study, the thermo-elastic behavior of an aluminum die cast die during the casting process is analyzed. The cyclic symmetry nature of the die geometry offers a simplified reduced model for the finite element simulation. It is assumed that the temperature distribution on the molten metal affected boundaries follows a smooth function variation while the free surfaces of the die experience a convection heat transfer type. Considering a particular boundary condition, the results of the current study conform to the available analytical solutions. A detailed sensitivity analysis is conducted to highlight the effects of die preheat, groove corner radius of curvature and the thermal barrier coatings. The results indicate that the die preheating before the casting process can significantly decrease the stress level within the system. Also, an increase in the radius of curvature for the groove corners may result in a 25% reduction of the von Mises stress around these crack susceptible zones. Application of hard chromium or a silicon nitride thermal barrier coating considerably increases the thermal shock strength of the die such that a 0.1mm thick hard chromium coating can decrease the maximum von Mises stress about 49% with respect to the non-coated specimen. Especially for a functionally graded coating type, the reduction in maximum von Mises stress is around 70% compared to the non-coated specimen. https://mej.aut.ac.ir/article_4146_109f91266ef89cc3690079b28abfe9a3.pdf