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Redesign of Die Internal Structure

Explore the finite element modeling approach for thermal and structural analysis of die internal structure. Sequentially coupled analysis, thermal material properties, and nonlinear structural properties analyzed using commercial software ANSYS and ABAQUS. Learn about geometry/mesh generation, coupled fields analysis, thermal stress analysis, plasticity, and visualization of results.

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Redesign of Die Internal Structure

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  1. Redesign of Die Internal Structure Dr. Henry Tan School of Mechanical, Aerospace and Civil Engineering The University of Manchester

  2. Finite Element Modeling ANSYS ABAQUS Thermal, structural analysis Commercial software: Mathematical details skipped

  3. Model Cooling Process Sequentially coupled thermal/structural analysis: Input of structural analysis depends on the results from thermal analysis.

  4. 1st step:Geometry/Mesh Generation

  5. 3D Mesh Generation Previous experience: 2D 3D Geometry description 3D mesh generation

  6. Same Mesh for Thermal/Structural Analysis Geometry description In sequentially coupled thermal/structural analysis: Same mesh Different thermal/structural element

  7. 2nd step:Coupled Fields Analysis

  8. Basics for Thermal Analysis Solve the heat balance equation Finite element solution gives: Nodal temperature

  9. Transient Thermal Analysis Need to define: Boundary condition Time dependent cooling load 50C/hour, to 500C Initial temperature distribution (at all nodes) 900C Initial condition

  10. Thermal Stress Analysis Solve the force balance equation Input: nodal temperatures that a transient thermal analysis calculates Output: thermal stresses

  11. Thermal Material Properties Thermal conductivity, 10.5 W/Km @ 20 C 30 W/Km @ 1000 C Temperature dependence ->Nonlinear thermal analysis

  12. Structural Material Properties Thermal expansion coefficient: 20-600C 17.8 x 10-6 20-800C 18.2 x 10-6 20-1000C 18.9 x 10-6 • 0.2% proof stress (as cast): 280 N/mm2@20C, • 195 N/mm2@870C • 110 N/mm2@900 C • 80 N/mm2@1000 C, • 45 N/mm2@1100 C • Ultimate Tensile Strength: 470 N/mm2@20C, • 250 N/mm2@870C, • 145 N/mm2@900C, • 92 N/mm2@1000C, • 53 N/mm2@1100C Plasticity -> Nonlinear structural analysis

  13. Results from Finite Element Modeling • Temperature-time curves for selected locations (corners) • Stress-time curves for selected locations (corners) • distortion-time curves for selected locations (corners) • Temperature field (picture) at selected cooling time • Stress field at selected cooling time • Deformation field at selected cooling time • Animation for temperature evolution on the die surface • Animation for stress evolution on the die surface • Animation for deformation evolution on the die surface

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