Die Casting Sub-Insert Design for Thermo Mechanical Fatigue

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Die casting dies have a limited useful life cycle due to thermo mechanical fatigue, leading to premature fracture and high production costs, especially when using special alloys for structural components in the automotive industry.

Innovation Solution

A method involving the production of fragmented dies where sub-inserts are designed with boundary lines located in zones most susceptible to thermo mechanical fatigue, using numerical simulations to identify and define these zones, allowing for assembly with attachment means to form the die, and enabling the use of different materials based on stress levels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If a single-piece die is used for die casting, then the structural integrity is maintained, but the useful life cycle is limited due to thermo mechanical fatigue causing fracture

Engineering Contradiction:

Improveuseful life cycle of dieVSAvoidstructural integrity of die

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The die is divided into multiple sub-inserts (first sub-insert, second sub-insert, etc.) that can be assembled together. The boundary lines between sub-inserts are strategically positioned in zones of greatest thermo mechanical fatigue, allowing the die to be segmented at the most vulnerable points while maintaining overall structural integrity through the assembly system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The die is pre-fractured or pre-fragmented during design by positioning boundary lines at zones most subject to fatigue. This preliminary segmentation prevents catastrophic failure by allowing controlled separation at predetermined locations where fatigue cracks would naturally propagate.

Inventive Principle:

Principle #10Preliminary action

2Duration of action of stationary object

If high-strength alloys are used throughout the entire die, then the useful life cycle is extended, but the production costs increase significantly

Engineering Contradiction:

Improveuseful life cycle of dieVSAvoidproduction cost of die

Core Design Contradiction:

Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

Different materials with appropriate properties are assigned to different sub-inserts based on their specific functional requirements and stress conditions. High-strength alloys are used only where necessary (in zones of greatest fatigue), while less resistant and more cost-effective materials are used in lower stress zones, optimizing both performance and cost.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The die assembly comprises multiple sub-inserts made from different materials, creating a composite structure where each material contributes its optimal properties to the specific zone it occupies. This allows the die to achieve high overall durability without uniformly using expensive high-strength alloys throughout.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11138353B2Method for designing dies for die casting and die

Publication Date: 2021.10.05 COSTAMP GRP SPA

AI summary

A method for making dies for die casting, and relative die, includes designing moulding parts of the die as plurality of sub-inserts. Each sub-insert of the plurality is bordered by boundary lines defined on the basis of a simulation of thermo mechanical behaviour of the die in operation. The simulation is performed by a processor of a computer and the behaviour is the behaviour of the die if the die were a single piece. The method also includes producing the plurality of sub-inserts and assembling the sub-inserts of the plurality with attachment means, so as to form the die.