Virtual Mold Technique in Thermal Stress Analysis during Casting Process

It is important to analyse the casting product and the mold at the same time considering thermal contraction of the casting and thermal expansion of the mold. The analysis considering contact of the casting and the mold induces the precise prediction of stress distribution and the defect such as hot tearing. But it is difficult to generate FEM mesh for the interface of the casting and the mold. Moreover the mesh for the mold domain spends lots of computational time and memory for the analysis due to a number of meshes. Consequently we proposed the virtual mold technique which only uses mesh of the casting part for thermal stress analysis in casting process. The spring bar element in virtual mold technique is used to consider the contact of the casting and the mold. In general, a volume of the mold is much bigger than that of casting part, so the proposed technique decreases the number of mesh and saves the computational memory and time greatly. In this study, the proposed technique was verified by the comparison with the traditional contact technique on a specimen. And the proposed technique gave satisfactory results.

DYNAMIC OPTIMIZATION OF THERMAL STRUCTURE

he temperature distnbution on the surface of a flight vehicle and the va-riation of the modulus of elasticity with respect to temperature are considered. The minimum weight structural design with constraints on frequency, on the coordinates ofmodal nodes and on the upper and lower bounds of the design vanables are studied us-ing Kuhn-Tucker conditions as optimal cntenon. The vanation of the flrst three ordernatural frequencies, modal shapes and minimum structural weight vs temperature gra-dient are discussed. It is pointed out that it is imperative to take into account the effectof aerodynamic heating on structural dynamic optimization. Calculation example showsthat the method obtained is feasible and efficient.

Numerical Analysis of Frictional Heat-Stress Coupled Field at Dynamic Contact

A new analysis method was developed to simulate the dynamic process of a frictional heat-stress coupled field. The relationship between the frictional heat and the thermal stress was investigated for concave cylinder contact conditions. The results show that, as a nonlinear contact problem, the frictional heat at the contact areas changes with moving velocity in both value and distribution, and that the transient frictional heat at the dynamic condition has a peak within a cycle. The dynamic process of friction heat and thermal stresses affects diffusion of the frictional effects. The result can be helpful for dynamic simulation of diffusion lubrication of elements at elevated temperatures.

BRAKE TEST OF SiCp/A356 BRAKE DISK AND INTERPRETATION OF EXPERIMENTAL RESULTS

Material properties are obvious different between aluminum matrix composites and iron and steel materials. After the brake disk braked at the same speed, the average temperature of the aluminum brake disk is 1.5 times as high as one of iron and steel brake disk, the thermal expansion value of the aluminum brake disk is 2 times as big as one of iron and steel brake disk. Mechanical property of the material decreases with the temperature increasing generally during braking, on the other hand, the big thermal stress in the brake disk happens because the material expansion is constrained. Firstly, the reasons of the thermal stress generation and the fracture failure of brake disks during braking are analyzed qualitatively by virtue of three-bar stress frame and sandwich deformation principles in physic, and then the five constraints which cause the thermal stress are summarized. On the base of the experimental results on the 1：1 emergency brake test, the thermal stress and temperature fields are simulated; The behavior of the fracture failure is interpreted semi-quantitatively by finite element analysis, There is the coincident forecast for the fraction position in term of the two methods. In the end, in the light of the analysis and calculation results, it is the general principles observed by the structure design and assembly of the brake disk that are summarized.

Numerical Analysis of Braking Discs for a Taurus Class Locomotive

This paper shows the thermal and stress analysis of the worn brake disc for a Taurus class locomotive. The numerical analyses are carried out under the experimental testing program,Priifprogramm No.5,which is adjusted for this type of locomotives by UIC CODE 541-3.The simulations results under mentioned program show the most unfavorable case of braking.The numerical analysis is done with the finite element method(FEM), using ABAQUS software.