A three-dimensional heat transfer numerical model during die casting cycles is developed by using the direct finite difference method in this paper. The boundary conditions of heat transfer during die casting process are deduced. I-DEAS is adopted as pre-processor which performs three-dimensional solid construction and automatic mesh. The temperature field of aluminum casting for auto engines has been simulated. Infrared Thermal Pictures for the die casting temperature are obtained. The simulated results are seen to be in good accordance with the infrared thermal picture. Primary reasons, which cause thermal fatigue crackle of die casting dies, are analyzed.
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