Simulation-based prediction of the fracture elongation as a failure criterion for thin-walled high-pressure die casting components

In this investigation a new approach of predicting the quality of High-Pressure Die Casting (HPDC) parts was achieved by correlating simulation data with mechanical properties derived by tensile testing. The tensile specimens were taken from a connector side member and door sill, a thin-walled automotive casting part from the rear car body structure. These tensile specimens are modelled in the numerical casting simulation with regard to their geometry and position in the casting part. The numerical evaluation of mean values for both common and modified simulation output parameters across each sampling site provides the data basis for comparison and correlation with the experimental test results. The correlation of mechanical properties from tensile testing and numerical simulation was verified by an average value of five parts. The result is a modified simulation output for the temperature, called temperature difference (▵T) with a critical value (Tc) to evaluate component areas meeting and not meeting the quality requirements of 8% fracture elongation. Not exceeding 8% fracture elongation is by far the highest quality issue of thin-walled automotive structural parts, manufactured by HPDC.