Hi everyone ,

I am simulating a low pressure die casting arrangement in which we need to know the effect of gap formation on heat conductance.
Now what is happening is my casting is moving in the y direction due to contraction but it is entering the mesh of the top die like it is overlapping, I have attached a figure for your reference.

Please can anyone tell me what is wrong that I am doing?

I have defined Normal contact with a penalty stiffness of 1E+09 to model that the material of the die and the casting is stiff this I have done in General contact in the initial step.

Also then I am using a GAPCON subroutine to study the impact of gao formation, contact pressure and temp on the heat conductance also which I have attached in the post.

Please can anyone tell what am I doing wrong, also can anyone check if the written GAPCON is correct?


if (temp(1) <= 550.00) then
 
if (d(2) <= 50000000 .and. d(2)>0.0) then
ak(1) = 0.000005* d(2) + 2600.00
ak(3) = 0.000005
 
elseif (d(2)==0) then 
 
if (d(1) >= 0.0 .and. d(1)<=0.0001) then
 
ak(1) = 2700.00 - 22000.00 * d(1)
ak(2) = -22000.00
 
elseif (d(1) >0.0001 .and. d(1)<=0.0002) then
 
ak(1) = 750.00 - 2500.00 * d(1)
ak(2) = -2500.00
 
elseif (d(1) > 0.0002) then
 
ak(1) = 250.00
ak(2) = 0.0
end if 
 
end if
 
elseif (temp(1) > 550.00 .and. temp(1) <= 610.00) then
 
ak(1) = 2.73 * temp(1) + 1034.7
ak(4) = 2.73
elseif(temp(1) > 610.00 .and. temp(1) <= 720.00) then
 
ak(1) = 3000.00
 
end if

Thanks