Simulation-driven product development of cast components with allowance for process-induced material behaviour

J Jansson,J Olofsson,K Salomonsson

doi:10.1093/jcde/qwaa008

J Jansson, J Olofsson + Show 1 more

Open Access

https://doi.org/10.1093/jcde/qwaa008

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Abstract

Abstract This paper presents a methodology that can be used to consider local variations in thermomechanical and thermophysical material properties, residual stresses, and strength-differential effects in finite element analyses of cast components. The methodology is based on applying process simulations and structural analyses together with experimentally established, or already available literature data, in order to describe element-specific material variations. A cast-iron cylinder head was used in order to evaluate the influence of several simplifications that are commonly performed in computer aided engineering. It is shown that non-trivial errors of a potentially large magnitude are introduced by not considering residual stresses, compressive behaviour, temperature dependence, and process-induced material property variations. By providing design engineers with tools that allow them to consider the complex relationships between these aspects early in the development phase, cast components have the potential to be further optimized with respect to both weight and performance.

Highlights

As society continues to strive towards the electrification of vehicles and reduction of emissions, demands for lightweight components with high robustness and load bearing capacity increase
This paper presents a methodology that can be used to consider local variations in thermomechanical and thermophysical material properties, residual stresses, and strength-differential effects in finite element analyses of cast components
The microstructural refinement associated with a short solidification time was seen in both the graphite perimeter and Feret max, which decreases with a reduction in solidification time

Summary

Introduction

As society continues to strive towards the electrification of vehicles and reduction of emissions, demands for lightweight components with high robustness and load bearing capacity increase. Casting is commonly used for this purpose due to the high degree of design freedom offered, as well as recyclability at a favourable cost. Numerical methods such as the finite element method and topology optimization are commonly applied in order to design and optimize cast components with regard to high load-bearing capacity and fatigue life (Citarella, Cricrı, Lepore, & Perrella, 2010), while simultaneously minimizing weight. During the solidification of pearlitic hypo-eutectic Flake Graphite Iron (FGI, known as grey cast iron), a dendritic austenite structure grows as the primary phase, the features of which are governed by the chemical composition and inoculation conditions (Dioszegi, Fourlakidis, & Loraegi, 2015). Graphite is precipitated together with eutectic austenite in a eutectic reaction, where the composition, cooling- and inoculation conditions determine the morphology of the graphite and size of the eutectic cells

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