Reverse Engineering for Surface Reproduction of Engine Block Water Jacket Insert and Thermal Stress Analysis for Water Jacket Insert Using Computer Stress Simulation

摘要

Thermal-mechanical fatigue is a common cause of failure in die casting dies used in the casting of aluminum alloys. During the die casting process, certain regions of the die cavity and die inserts experience a combination of thermal distortions and large stresses. These regions of the die and die inserts lead to premature failure resulting in considerable cost and machine downtime. Modeling these thermal-mechanical fatigue stresses in the die cavity or in die inserts is of considerable benefit to die designers and die casters for trouble shooting or die modification. Sometimes, due to the lack of die design information, reverse engineering is often implemented in retrieving the original design. This paper discusses results of a case study carried out by using reverse engineering technology to retrieve water jacket insert data, and then conduct a stress simulation for this water jacket insert.