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Jain Master's Thesis.pdf (2.04 MB)

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Design and LENS® Fabrication of Bi-metallic Cu-H13 Tooling for Die Casting

Jain, Akshay Ashok
http://rave.ohiolink.edu/etdc/view?acc_num=osu1385987045

Abstract Details

2013, Master of Science, Ohio State University, Industrial and Systems Engineering.
Thermal fatigue is one of the most common causes leading to die failure in die casting. This thesis investigates and presents the results of thermal fatigue life in a bi-metallic H13-Copper die which can be manufactured using laser additive manufacturing technologies now commercially available. Using finite element method, computational models are developed to simulate the thermal fatigue tests of Wallace (Benedyk, Moracz, and Wallace 1970). Numerical solutions to the thermal-mechanical problem are obtained. The solutions include temperature, strain and stress distributions within the test sample. Solutions were obtained for varying amounts of copper in the test sample geometry. Results from the pure H13 sample computational model compared very well with experimental values obtained by Wallace (Benedyk, Moracz, and Wallace 1970). The maximum temperature reached by the test sample is shown to decrease with increasing amounts of copper. The fatigue life is calculated using the `method of universal slopes’ which relates the calculated cyclic strain ranges to the number of cycles necessary for fatigue crack initiation. The specimen geometry consisting of a half thickness of Cu and the other half thickness of H13 at the thinnest point in the full cross-section of the wall thickness was shown to provide the best balance between thermal and fatigue life performance.
Jerald Brevick (Advisor)
88 p.
Engineering; Industrial Engineering; Mechanical Engineering; Metallurgy
Die Casting; Bi-metallic tooling; Copper; H13; Die Casting Tooling; Ansys; Finite Element Analysis; FEA; Thermal Fatigue Die Casting; Laser Engineered Net Shaping; Laser Additive Manufacturing; Copper-H13; H13-Copper; Cu-H13; H13-Cu; Dunk Test;

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Citations

  • Jain, A. A. (2013). Design and LENS® Fabrication of Bi-metallic Cu-H13 Tooling for Die Casting [Master's thesis, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1385987045

    APA Style (7th edition)

  • Jain, Akshay. Design and LENS® Fabrication of Bi-metallic Cu-H13 Tooling for Die Casting. 2013. Ohio State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1385987045.

    MLA Style (8th edition)

  • Jain, Akshay. "Design and LENS® Fabrication of Bi-metallic Cu-H13 Tooling for Die Casting." Master's thesis, Ohio State University, 2013. http://rave.ohiolink.edu/etdc/view?acc_num=osu1385987045

    Chicago Manual of Style (17th edition)

osu1385987045
1,061
© 2013, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.