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USING A SIMULATION PROGRAMME TO PREDICT DISTORTION OF CAST IRON CASTINGS
Abstract
The increasing computing power of modern hardware systems opens new possibilities for simulating complex solidification phenomena as well as the overall simulation of the casting process. Although the simulation of filling and solidification can be considered to be state of the art, the simulation of residual stresses and distortion is still the object of intensive research. Distortion is one of often found problems of castings, especially large castings with thin sections such as frame shape or those with curved surfaces. To predict distortion, it is necessary to perform thermal and stress analysis of castings because distortions is the result of non-uniform cooling and closely related to the behavior of casting material. Distortion prediction is usually designated by displacement results directly obtained from stress analysis. For numerical simulation, the casting design has to be enmeshed to finite difference (FD) or finite element (FE) models for thermal and stress analysis, erformed using finite element modeling. The paper deals with the stresses in castings that cause casting distortion. The formation and course of distortion is monitored by means of a simulation program that allows their elimination or minimization on real castings.
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