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Reducing Stress Concentrations 

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The initial design of the heat sink block had sharp edges and corners on the top face (which sits deep in the die cavity).  The casting engineer had three choices in designing the top face of the heat sink block -- 
No radius on the edges,  1/4" radius on the edges, and 1/2" radius on the edges

Which design choice (no radius, 1/4" radius, 1/2" radius) is best,  considering the need to eliminate sharp edges and reduce stress concentrations without sacrificing needed thermal mass?
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Copyright 2005  by the North American Die Casting Assoc. All rights reserved. 
Comments to: udvardy@diecasting.org
Last Modified:January, 2005 by STG

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Die Casting