In this study, residual stresses in heat treated specimen were measured by using ESPI (Electronic Speckle-Pattern Interferometry) combined with the hole-drilling method.The specimen, made of SUS 304 austenitic stainle...In this study, residual stresses in heat treated specimen were measured by using ESPI (Electronic Speckle-Pattern Interferometry) combined with the hole-drilling method.The specimen, made of SUS 304 austenitic stainless steel, was quenched and water cooled to room temperature.Numerical simulation using a hybrid FDM/FEM package was also carried out to simulate the heat treatment process.As a result, the thermal stress fields were obtained from both the experiment and the numerical simulation.By comparision of stress fields, results from the experimental method and numerical simulation well agreed to each other, therefore, it is proved that the presented experimental method is applicable and reliable for heat treatment induced residual stress measurement.展开更多
Most computational structural engineers are paying more attention to applying loads rather than to DBCs （Displacement Boundary Conditions） because most static stable mechanical structures are working under already p...Most computational structural engineers are paying more attention to applying loads rather than to DBCs （Displacement Boundary Conditions） because most static stable mechanical structures are working under already prescribed displacement boundary conditions. In all of the computational analysis of solving a system of algebraic equations, such as FEM （Finite Element Method）, three translational and three rotational degrees of freedom （DOF） should be constrained （by applying DBCs） before solving the system of algebraic equation in order to prevent rigid body motions of the analysis results （singular problem）. However, it is very difficult for an inexperienced engineer or designer to apply proper DBCs in the case of thermal stress analysis where no prescribed DBCs or constraints exist, for example in water quenching for heat treatment. Moreover, improper DBCs cause incorrect solutions in thermal stress analysis, such as stress concentration or unreasonable deformation phases. To avoid these problems, we studied a technique which performs the thermal stress analysis without any DBCs; and then removes rigid body motions from the deformation results in a post process step as the need arises. The proposed technique makes it easy to apply DBCs and prevent the error caused by improper DBCs. We proved it was mathematically possible to solve a system of algebraic equations without a step of applying DBCs. We also compared the analysis results with those of a traditional procedure for real castings.展开更多
Solidif ication and f luid f low analysis using computer simulation is a current common practice. There is also a high demand for thermal stress analysis in the casting process because casting engineers want to contro...Solidif ication and f luid f low analysis using computer simulation is a current common practice. There is also a high demand for thermal stress analysis in the casting process because casting engineers want to control the defects related to thermal stresses, such as large deformation and crack generation during casting. The riser system is an essential part of preventing the shrinkage defects in the casting process, and it has a great inf luence on thermal phenomena. The analysis domain is dramatically expanded by attaching the riser system to a casting product due to its large volume, and it makes FEM mesh generation diff icult. However, it is diff icult to study and solve the above proposed problem caused by riser system using traditional analysis methods which use single numerical method such as FEM or FDM. In this paper, some research information is presented on the effects of the riser system on thermal stress analysis using a FDM/FEM hybrid method in the casting process simulation. The results show the optimal conditions for stress analysis of the riser model in order to save computation time and memory resources.展开更多
Shrinkage cavity may be detrimental to mechanical performances of casting parts.As a consequence,design engineers often use overly large safety factors in many designs due to insufficient understanding of quantitative...Shrinkage cavity may be detrimental to mechanical performances of casting parts.As a consequence,design engineers often use overly large safety factors in many designs due to insufficient understanding of quantitative effects of shrinkage cavity defects.In this paper,process of Al alloy wheel impact test was computationally analyzed for both the wheel models with and without shrinkage cavity defects.Based on shrinkage cavity data obtained from industrial CT (Computerized Tomography),the shrinkage cavity defects were modeled with SSM (Shape Simplification Method),which reconstructs shrinkage cavity defects to hollow spheroid primitives.After the impact simulation was conducted,the results show that under impact test condition,the wheel considering shrinkage cavity defects may fracture while the sound-assumed wheel may not.展开更多
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 mo...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.展开更多
文摘In this study, residual stresses in heat treated specimen were measured by using ESPI (Electronic Speckle-Pattern Interferometry) combined with the hole-drilling method.The specimen, made of SUS 304 austenitic stainless steel, was quenched and water cooled to room temperature.Numerical simulation using a hybrid FDM/FEM package was also carried out to simulate the heat treatment process.As a result, the thermal stress fields were obtained from both the experiment and the numerical simulation.By comparision of stress fields, results from the experimental method and numerical simulation well agreed to each other, therefore, it is proved that the presented experimental method is applicable and reliable for heat treatment induced residual stress measurement.
文摘Most computational structural engineers are paying more attention to applying loads rather than to DBCs （Displacement Boundary Conditions） because most static stable mechanical structures are working under already prescribed displacement boundary conditions. In all of the computational analysis of solving a system of algebraic equations, such as FEM （Finite Element Method）, three translational and three rotational degrees of freedom （DOF） should be constrained （by applying DBCs） before solving the system of algebraic equation in order to prevent rigid body motions of the analysis results （singular problem）. However, it is very difficult for an inexperienced engineer or designer to apply proper DBCs in the case of thermal stress analysis where no prescribed DBCs or constraints exist, for example in water quenching for heat treatment. Moreover, improper DBCs cause incorrect solutions in thermal stress analysis, such as stress concentration or unreasonable deformation phases. To avoid these problems, we studied a technique which performs the thermal stress analysis without any DBCs; and then removes rigid body motions from the deformation results in a post process step as the need arises. The proposed technique makes it easy to apply DBCs and prevent the error caused by improper DBCs. We proved it was mathematically possible to solve a system of algebraic equations without a step of applying DBCs. We also compared the analysis results with those of a traditional procedure for real castings.
文摘Solidif ication and f luid f low analysis using computer simulation is a current common practice. There is also a high demand for thermal stress analysis in the casting process because casting engineers want to control the defects related to thermal stresses, such as large deformation and crack generation during casting. The riser system is an essential part of preventing the shrinkage defects in the casting process, and it has a great inf luence on thermal phenomena. The analysis domain is dramatically expanded by attaching the riser system to a casting product due to its large volume, and it makes FEM mesh generation diff icult. However, it is diff icult to study and solve the above proposed problem caused by riser system using traditional analysis methods which use single numerical method such as FEM or FDM. In this paper, some research information is presented on the effects of the riser system on thermal stress analysis using a FDM/FEM hybrid method in the casting process simulation. The results show the optimal conditions for stress analysis of the riser model in order to save computation time and memory resources.
文摘Shrinkage cavity may be detrimental to mechanical performances of casting parts.As a consequence,design engineers often use overly large safety factors in many designs due to insufficient understanding of quantitative effects of shrinkage cavity defects.In this paper,process of Al alloy wheel impact test was computationally analyzed for both the wheel models with and without shrinkage cavity defects.Based on shrinkage cavity data obtained from industrial CT (Computerized Tomography),the shrinkage cavity defects were modeled with SSM (Shape Simplification Method),which reconstructs shrinkage cavity defects to hollow spheroid primitives.After the impact simulation was conducted,the results show that under impact test condition,the wheel considering shrinkage cavity defects may fracture while the sound-assumed wheel may not.
文摘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.
