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Chabod A.,Ctif Center Technique Des Industries Of La Fonderie | Longa Y.,Ctif Center Technique Des Industries Of La Fonderie | Dracon J.M.,Ctif Center Technique Des Industries Of La Fonderie | Chailler K.,Ctif Center Technique Des Industries Of La Fonderie | And 2 more authors.
IOP Conference Series: Materials Science and Engineering | Year: 2012

Digital simulation (QuikCAST, ProCAST) is already used extensively when designing metallic dies for founding, in particular to design filling and gating systems. Simulation of the steady-state temperature cycles of dies has also been mastered. With large castings, the temperature gradient induced between the moulding surface and the rear surfaces of the die leads to deformations that may be large enough to measure, and incompatible with the required dimensional accuracy. The temperature gradient also creates thermal fatigue stresses that cause crazing of the die surface. In the study conducted by CTIF, aimed at measuring tooling deformations, various ways of measuring displacements at high temperatures (with and without contact) were investigated in order to evaluate their capabilities and limitations. An experimental device was designed - a test bench combining a metallic die having a simple geometry, in which an aluminium part could be cast, and instrumentation (temperature and displacement sensors). The deformations of the die were measured during first cycles of temperature homogenization. Concurrently, thermomechanical calculations were carried out on the same geometry using PROCAST. The calculation results are well correlated with the experimental measurements and validate the tools and the calculation methods. This thermomechanical approach makes it possible to optimize die design in the foundry and to predict high-temperature deformations as early as the design stage. Knowledge of these deformations makes it possible in turn to anticipate the geometrical and dimensional variations undergone by the castings themselves and so to improve their accuracy. The designer can act on the temperature of the die or the design of the casting, or create a die in which the expected thermal deformation is reversed so as to produce a casting having the correct dimensions. In short, thermomechanical simulation can be applied to this problem to achieve a better understanding of the phenomena and to test solutions in advance. © Published under licence by IOP Publishing Ltd. Source

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