The die casting process involves the repeated casting and spray cooling (or air cooling) in a die cavity. The trace of temperature variation of a die usually shows up with a cyclic steady state after about 10 cycles. This paper describes a new thermal analysis method (Cyclic Steady heat balance Method, CSM), which can predict the die temperature at a cyclic steady state without a repeated numerical calculation. In CSM, three kinds of mean cavity surface temperatures, i. e. during casting, spray cooling and one cycle, are taken into consideration. Since relations between the temperature and cooling parameters (cast time, spray time, cooling strength, etc) are expressed analytically, the effect of cooling conditions on the die temperature can be easily surveyed. Mean temperature distribution within a die can be also calculated by CSM. Assuming it as a initial condition of the die, solidification analysis in a cyclic steady state can efficiently be done.
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