Numerical simulation and defect elimination in the casting of truck rear axle using a nodular cast iron

Sun, Yuanxi; Luo, Jing; Guofa, MI; Lin, Xin

doi:10.1016/j.matdes.2010.11.009

Cited by 29 publications

(10 citation statements)

References 18 publications

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“…The improvement in casting design using simulations is well reported in previously published literature [2][3][4]. Bhatt et al optimized the manually designed feeding system to minimize shrinkage in a cast iron gear box.…”

Section: Introductionmentioning

confidence: 65%

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Simulation-Based Mould Design, Life Prediction and Reliability Assessment of a Valve Body

Khan¹,

Sheikh²

2021

Int. j. simul. model.

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Shrinkage porosities are one of the major casting defects which affects the quality and structural integrity of cast products. Consequently, the service life and reliability of the components are questioned and need to be determined prior to put these parts in service. This study presents a simulation based methodology for mould design, life prediction, and reliability assessment of castings using simulation tools. The methodology is developed and validated for standard test specimens followed by its application on a valve body. The mould design is optimized for porosities using MAGMASoft. Integration of predicted minimum porosity to valve body is done using MAGMAlink. The stress fields with porosity are obtained using ABAQUS which are then used to predict life and estimate reliability. Infinite life i.e. more than 10 6 cycles is predicted with minimum porosity in valve body. The reliability results for valve under normal operating pressure i.e. 1 MPa shows ~100 % reliability for infinite life, however, under the maximum loading conditions i.e. 2.5 MPa, the reliability is significantly compromised. A safe load-induced stress on valve is also determined based on the reliability results.

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Section: Introductionmentioning

confidence: 65%

“…75 %, 78 %, and 80 % which was previously ~72 % in the existing method of casting. Sun et al [3] presented the design optimization for a cast iron truck rear axle. Temperature and flow related defects were predicted using 3D FDM model and the Z-CAST software.…”

Section: Introductionmentioning

confidence: 99%

Simulation-Based Mould Design, Life Prediction and Reliability Assessment of a Valve Body

Khan¹,

Sheikh²

2021

Int. j. simul. model.

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“…Numerical simulation can be used to shorten the material development cycle effectively, but the application of this technology in cast irons is not so mature because main intensive studies of cast irons are much earlier than the emergence of numerical simulation [21] . Because cast iron is considered as a structural material, simulations of cast irons in the past were mainly focused on the microstructure formation [42][43][44][45] during solidification process and mechanical behavior [46][47][48] , those on thermal conductivity are rarely reported. Velichko et al [20,49] used focused ion beam (FIB) tomography to analyze the 3-D morphologies of different types of graphites.…”

Section: Numerical Simulationmentioning

confidence: 99%

Thermal conductivity of cast iron -A review

Wang

2020

China Foundry

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C ast irons are among the most widely used metallic materials due to their good mechanical and physical properties, excellent casting ability and low cost. According to the survey of Modern Casting [1] , as shown in Fig. 1, outputs of lamellar graphite cast iron (LGI) are much higher than that of spheroidal graphite cast iron (SGI) though SGI has better mechanical properties. One of the reasons is that LGI has wide applications at high temperatures due to its superior thermal conductivity. That's why the LGI and compacted graphite cast iron (CGI) are widely applied in brake disc, engine block and cylinder head [2][3][4][5] . The thermal conductivity is an extremely important performance index for cast irons. The high thermal conductivity can help to transfer heat rapidly and prevent thermo-mechanical fatigue, deformation and hot cracking, thereby ensuring the applications of cast irons in more complex or harsher conditions and improving the service life of products [6] . Therefore, on the premise of basic mechanical properties, the design and development of high thermal conductivity cast irons is one of the key points in the research and development of cast irons.Cast irons are multi-component alloys with regular elements of C and Si and some commonly added alloying elements, such as Mn, Cu, Ni, Cr, W, Mo, V, Ti, Al, etc. The microstructure of cast irons is complicated, usually composed of ferrite, pearlite, graphite, and cementite. So, the thermal conductivity of cast irons is dependent on both the alloying elements and structural constituents.During solidification, the formation of cast iron microstructure, especially the graphite morphology, is governed by the difference in thermal conductivity between graphite and austenite in eutectic couple, and between different orientations of graphite crystals [7] . According to different graphite morphologies, cast irons where carbon precipitated in the form of graphite (graphite cast irons) are mainly divided into LGI with lamellar graphite, CGI with compacted graphite and SGI with spheroidal graphite. Generally, the thermal

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“…Efforts have been made in the past to obtain high-quality defect-free castings by developing an in-depth understanding of the areas such as (a) design of runner and gating systems, 32–40 (b) design of feeding systems (locations and number of risers), 41–45 (c) filling and solidification during different casting processes, 46–50 (d) casting process parameters (thermo-physical data, injection parameters, etc. ), 50–54 (e) stress distribution in cast products, 55–59 and (f) quality control and assurance of the cast products.…”

Section: Case Studies Using Casting Simulation Toolsmentioning

confidence: 99%

Simulation tools in enhancing metal casting productivity and quality: A review

Khan

Sheikh

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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Casting simulation softwares are increasingly being used in modern foundries and metal casting industries. Softwares simulate the casting process in a virtual domain and provide insight into mold filling, solidification and cooling, and casting defects. Casting simulations allow designers to model, verify, and validate the process followed by optimization of design and process parameters before they actually put into practice. This article aims at exploring the methods of modeling and simulation of metal casting processes with reference to some related case studies. Most commonly available casting simulation softwares and the underlying mathematical models used are briefly introduced. Casting process simulation together with the results obtained is well explained. Case studies from the literature revealed that simulation tools are playing a vital role in producing high-quality defect-free cast products by providing an in-depth understanding of mold filling and solidification, gating, runner and feeding system design, and other process parameters. Recent efforts on integrating the casting simulations to mechanical performance simulations are discussed which is quite promising in predicting the service life of cast products. It is concluded that simulations have been well established in metal casting processes and more developments in simulation tools are needed for reliability prediction of castings.

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Numerical simulation and defect elimination in the casting of truck rear axle using a nodular cast iron

Cited by 29 publications

References 18 publications

Simulation-Based Mould Design, Life Prediction and Reliability Assessment of a Valve Body

Simulation-Based Mould Design, Life Prediction and Reliability Assessment of a Valve Body

Thermal conductivity of cast iron -A review

Simulation tools in enhancing metal casting productivity and quality: A review

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