Numerical modelling of magnesium die-castings using stochastic fracture parameters

Quasi-static material tests using specimens cut from a generic cast component are performed to study the behaviour of the high-pressure die-cast magnesium alloy AM60 under different stress states. The experimental data set is applied to establish a validated probabilistic methodology for finite element modelling of thin-walled die-castings subjected to quasi-static loading. The test specimens are modelled in the explicit finite element (FE) code LS-DYNA using shell elements. The cast magnesium alloy AM60 is modelled using an elasto-plastic constitutive model including a high-exponent, isotropic yield criterion, the associated flow law and isotropic hardening. To simulate fracture, the Cockcroft–Latham fracture criterion is adopted, and the fracture parameter is chosen to follow a modified weakest-link Weibull distribution. Comparison between the experimental and predicted behaviour of the cast magnesium specimens gives very promising results.