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Metals 2017, 7(6), 191; doi:10.3390/met7060191

Experimental Investigation of Thermal Fatigue Die Casting Dies by Using Response Surface Modelling

1
Faculty of Mechanical Engineering, University Malaysia Pahang, Pekan 26600, Malaysia
2
Faculty of Manufacturing Engineering, University Malaysia Pahang, Pekan 26600, Malaysia
3
Baghdad-Institute, Foundation of Technical Education, Baghdad 10074, Iraq
*
Author to whom correspondence should be addressed.
Academic Editor: Filippo Berto
Received: 7 March 2017 / Revised: 24 April 2017 / Accepted: 25 April 2017 / Published: 26 May 2017
(This article belongs to the Special Issue Fatigue Damage)
View Full-Text   |   Download PDF [3298 KB, uploaded 1 June 2017]   |  

Abstract

Mechanical and thermal sequences impact largely on thermo-mechanical fatigue of dies in a die casting operations. Innovative techniques to optimize the thermo-mechanical conditions of samples are major focus of researchers. This study investigates the typical thermal fatigue in die steel. Die surface initiation and crack propagation were stimulated by thermal and hardness gradients, acting on the contact surface layer. A design of experiments (DOE) was developed to analyze the effect of as-machined surface roughness and die casting parameters on thermal fatigue properties. The experimental data were assessed on a thermo-mechanical fatigue life assessment model, being assisted by response surface methodology (RSM). The eminent valuation was grounded on the crack length, hardness properties and surface roughness due to thermal fatigue. The results were analyzed using analysis of variance method. Parameter optimization was conducted using response surface methodology (RSM). Based on the model, the optimal results of 26.5 μm crack length, 3.114 μm surface roughness, and 306 HV0.5 hardness properties were produced. View Full-Text
Keywords: response surface methodology; machining parameters; design of experiments; thermal fatigue response surface methodology; machining parameters; design of experiments; thermal fatigue
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MDPI and ACS Style

Abdulhadi, H.A.; Ahmad, S.N.A.S.; Ismail, I.; Ishak, M.; Mohammed, G.R. Experimental Investigation of Thermal Fatigue Die Casting Dies by Using Response Surface Modelling. Metals 2017, 7, 191.

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