Inserted Tool Design Using Finite Element Analysis

Elkhart Industrial Division of Amcast Industrial Corporation has developed the FORMCAST™ process to manufacture near-net shape components. Tooling used for this process consists of complex shaped cavities subjected to very high forming pressure. It is a common practice to use inserts that reduce stresses in such tooling.

This paper will describe how a general purpose Finite Element Analysis (FEA) software can be used to develop inserted tooling designs. FEA simulations will be discussed for two different inserted tooling designs, one using interference fit, and other using slide fit. Data presented in this paper will explain the computer models and analysis iterations used to develop optimal inserted tooling designs.