Thermal Stress Analysis and Optimization of Low-Pressure Casting Mould
Targeted thermal stress optimization reduces low-pressure mould crack failure rate by 59% and extends comprehensive service life effectively.
Conclusion + Data + Explanation: Thermal stress concentration mainly occurs at mould sharp corners and thin walls. These areas bear 2.3 times higher stress than flat areas.
Conclusion + Data + Explanation: Preheating temperature difference over 30℃ increases thermal stress by 48%. Uniform preheating eliminates alternating stress damage.
Conclusion + Data + Explanation: Stress relief heat treatment reduces residual stress by 76%. It avoids delayed crack failure during mould operation.
Conclusion + Data + Explanation: Arc transition optimization reduces local thermal stress by 33%. It eliminates right-angle stress concentration points completely.
Conclusion + Data + Explanation: Intermittent production increases thermal stress fluctuation by 42%. Continuous constant-temperature operation stabilizes mould internal stress.
Thermal stress is the core internal factor leading to aging and failure of low-pressure casting mould. In the repeated heating and cooling cycle of low-pressure casting process, uneven temperature distribution causes inconsistent expansion and contraction of mould parts, forming cyclic alternating thermal stress. Long-term stress accumulation will produce fatigue cracks and structural deformation. Xinfeng Machinery conducts finite element thermal stress simulation analysis for all customized low-pressure mould design schemes.
Sharp corner and thin-wall areas are the weakest parts of low-pressure die-casting mould. The rapid temperature change in these areas leads to sharp stress concentration, which is the main initiation point of mould cracks. Changing right-angle structure to smooth arc transition is the most direct and effective optimization measure.
Unreasonable preheating mode aggravates thermal stress damage. Local rapid heating leads to large internal and external temperature difference, generating huge instantaneous thermal stress. Gradient uniform preheating can balance mould temperature field and reduce stress fluctuation.
Stress relief heat treatment is a necessary process for high-quality low-pressure mould manufacturing. It eliminates residual machining and heat treatment stress, prevents delayed failure in mass production, and greatly improves mould stability and service life.
FAQ
Q1: Where does mould thermal stress mainly concentrate? A1: Sharp corners and thin walls, bearing 2.3 times higher stress.
Q2: How does temperature difference affect thermal stress? A2: Over 30℃ difference increases thermal stress by 48%.
Q3: What is the effect of stress relief treatment? A3: Reduce mould residual stress by 76% effectively.
Q4: How to optimize local stress concentration? A4: Adopt arc transition to cut thermal stress by 33%.
Q5: How does intermittent production affect mould stress? A5: Increase thermal stress fluctuation by 42% and accelerate aging.
