Abstract
Commonly available foundry simulation codes such as NovaFlow & Solid, Magma or ProCAST contain modules that allow to predict thermo-mechanical phenomena during the cooling of castings. However, due to the limited quantity and quality (certainty) of the values of mechanical parameters contained in databases, they are not readily used by the industry. The codes remain in the sphere of scientific considerations concerning mainly cast iron alloy castings. The article describes the problem of stress prediction in aluminum alloy castings. An experimental and virtual research methodology for the verification of residual (thermal) stress has been developed. As part of the methodology, a modified stress test has been developed, which uses a stress lattice. The location of the gating system has been modified, and to prevent the formation of shrinkage cavities, chills have been used. Moreover, in order to obtain higher rigidity of the structure, thin steel rods have been inserted before the pouring process. Such a solution has made it possible to conduct experimental simulation validation of the NovaFlow & Solid simulation code Stress module.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Ravi, B.: Computer-aided casting design and simulation. STTP. V.N.I.T, Nagpur, 21 July 2009
Ignaszak, Z.: Virtual Prototyping in Foundry Technology, Databases and Validation. Monograph. Publishing House of Poznan University of Technology, Poznan (2002). (in Polish)
Motoyama, Y., Inukai, D., Okane, T.: Verification of the simulated residual stress in the cross section of gray cast iron stress lattice shape casting via thermal stress analysis. Metall. Mater. Trans. A 45A, 2135–2325 (2014)
Johnson, E.M., Watkins, T.R., Schmidlin, J.E., Dulter, S.A.: A benchmark study on casting residual stress. Metall. Mater. Trans. A 43A, 1487–1496 (2012)
Gustafsson, E., Hofwing, M., Strömberg, N.: Residual stress in a stress lattice experiments and finite element simulation. J. Mater. Process. Technol. 209, 4320–4328 (2009)
Mochnacki, B., Suchy, J.: Modeling and Simulation of Casting Solidification. PWN, Warsaw (2015)
Suchy, J.: Segregation of alloying elements during directional coagulation (habilitation dissertation), Cracow, Issue 743 (2015). (Science notebooks of Silesian University of Technology)
Chiumenti, M., Agelet de Saracibar, C., Cervera, M.: On the numerical modeling of the thermomechanical contact for metal casting analysis. J. Heat Transf. 130, 061301 (2008)
Thomas, B.G.: Modeling of Hot tearing and other defects in casting processes. ASM Handb. 22, 362–374 (2009)
Stefanescu, D.M.: Methodologies for modeling of solidification microstructure and their capabilities. ISIJ 35(6), 637–650 (1995)
Kapturkiewicz, W.: Modeling of Crystallization of Cast Iron Castings. Monographs Series, vol. 2 (2003)
Polish standard BN-80/4051-02
Acknowledgments
The research work reported here was supported by the Polish Ministry of Science and Education grants no 02/25/DSPB/4521.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2019 Springer Nature Switzerland AG
About this paper
Cite this paper
Hajkowski, J., Sika, R., Hajkowski, M., Ignaszak, Z., Popielarski, P. (2019). Thermo-Mechanical Phenomena in Aluminum Alloy Casting During Cooling – Experimental Simulation. In: Gapiński, B., Szostak, M., Ivanov, V. (eds) Advances in Manufacturing II. MANUFACTURING 2019. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-16943-5_32
Download citation
DOI: https://doi.org/10.1007/978-3-030-16943-5_32
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-16942-8
Online ISBN: 978-3-030-16943-5
eBook Packages: EngineeringEngineering (R0)