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Casting and stress-strain simulations of a cast ductile iron component using microstructure based mechanical behavior
Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.ORCID iD: 0000-0003-2671-9825
Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
2012 (English)In: IOP Conference Series: Materials Science and Engineering, Volume 33: MCWASP XIII: International Conference on Modeling of Casting, Welding and Advanced Solidification Processes / [ed] Andreas Ludwig, Menghuai Wu and Abdellah Kharicha, London: IOP Publishing , 2012Conference paper, Published paper (Refereed)
Abstract [en]

The industrial demand for increased component performance with concurrent reductions in component weight, development times and verifications using physical prototypes drives the need to use the full potential of casting and Finite Element Method (FEM) simulations to correctly predict the mechanical behavior of cast components in service. The mechanical behavior of the component is determined by the casting process, and factors as component geometry and casting process parameters are known to affect solidification and microstructure formation throughout the component and cause local variations in mechanical behavior as well as residual stresses. Though residual stresses are known to be an important factor in the mechanical behavior of the component, the importance of local mechanical behavior is not well established and the material is typically considered homogeneous throughout the component. This paper deals with the influence of solidification and solid state transformation on microstructure formation and the effect of local microstructure variations on the mechanical behavior of the cast component in service. The current work aims to investigate the coupling between simulation of solidification, microstructure and local variations in mechanical behavior and stress-strain simulation. This is done by performing several simulations of a ductile iron component using a recently developed simulation strategy, a closed chain of simulations for cast components, able to predict and describe the local variations in not only elastic but also plastic behavior throughout the component by using microstructural parameters determined by simulations of microstructural evolution in the component during the casting process. In addition the residual stresses are considered. The results show that the FEM simulation results are significantly affected by including microstructure based mechanical behavior. When the applied load is low and the component is subjected to stress levels well below the yield strength of the material, the residual stresses highly affects the simulation results while the effect of local material behavior is low. As the applied load increases and the stress level in the component approaches and passes the yield strength, the effect of residual stresses diminishes while the effect of local mechanical behavior increases. In particular the predicted strain level is heavily affected by the use of local mechanical behavior. It is proposed that it is important to include both local mechanical behavior and residual stresses in stress-strain simulations to predict the true mechanical behavior of the component.

Place, publisher, year, edition, pages
London: IOP Publishing , 2012.
Series
IOP Conference Series, ISSN 1757-8981 ; 33
Keyword [en]
Casting, Component behaviour, Ductile iron, Mechanical behaviour, Plastic behaviour
National Category
Metallurgy and Metallic Materials Mechanical Engineering
Identifiers
URN: urn:nbn:se:hj:diva-19107DOI: 10.1088/1757-899X/33/1/012051OAI: oai:DiVA.org:hj-19107DiVA: diva2:542992
Conference
MCWASP XIII: International Conference on Modeling of Casting, Welding and Advanced Solidification Processes, Schladming, Austria, 17-22, June 2012
Projects
CompCAST
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xAvailable from: 2012-08-06 Created: 2012-08-06 Last updated: 2017-08-14Bibliographically approved
In thesis
1. Microstructure-based Mechanical Behaviour in Structural Analyses of Cast Components
Open this publication in new window or tab >>Microstructure-based Mechanical Behaviour in Structural Analyses of Cast Components
2012 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

In the process of developing cast iron and cast aluminium components, the co-operation between product development and production is important. On the engineering level, this co-operation is limited already in the product development phase e.g. by the lack of established methods to consider the mechanical behaviour of the completed component.

This thesis aims to increase the possibilities for co-operation in the product realisation process between product development and production by enabling the use of predicted local mechanical behaviour in structural analyses of cast components. A literature review on existing simulation methods and a work on characterization of mechanical behaviour from microstructural features are performed to identify important knowledge gaps. A simulation strategy is formulated that is able to predict local mechanical behaviour throughout the entire component and incorporate the behaviour into a Finite Element Method (FEM) simulation of the structural behaviour of the component. In the simulation strategy, the component specific microstructure-based mechanical behaviour is predicted using a casting process simulation. A computer program is developed to create FEM material definitions that capture the local variations in mechanical behaviour throughout the component.

The relevance of the simulation strategy is demonstrated for a ductile iron component. It is found that the local variations in mechanical behaviour result in a stress-strain distribution in the component that a homogeneous material description fails to express. Residual stresses affect the mechanical behaviour at low loads. At higher loads, however, the accuracy of the simulation is determined by the local variations in mechanical behaviour. Using a material reduction technique, the local mechanical behaviour can be incorporated without increasing the FEM simulation time. 

Place, publisher, year, edition, pages
Jönköping: School of Engineering, Jönköping University, 2012. 42 p.
Series
JTH Dissertation Series, 1
Keyword
Component behaviour, Structural analysis, Mechanical behaviour, Casting process simulation, Finite element method simulation
National Category
Mechanical Engineering Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-19127 (URN)978-91-87289-01-9 (ISBN)
Presentation
2012-08-31, Jönköpings Tekniska Högskola, E1405 Gjuterisalen, Gjuterigatan 5, Jönköping, 10:00 (Swedish)
Opponent
Supervisors
Available from: 2012-08-09 Created: 2012-08-08 Last updated: 2016-01-18Bibliographically approved
2. Simulation of Microstructure-based Mechanical Behaviour of Cast Components
Open this publication in new window or tab >>Simulation of Microstructure-based Mechanical Behaviour of Cast Components
2014 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

In the process of developing cast iron and cast aluminium components, a high level of co-operation between product development and production is of great importance. From an engineering standpoint, this co-operation is limited early in the product development phase by e.g. a lack of established methods for the consideration of local variations in the mechanical behaviour of a finished component.

This thesis aims to increase the possibilities for co-operation between product development and production during the product realisation process by introducing and studying the use of predicted local mechanical behaviour in structural analyses of cast components. A literature review of existing simulation methods and a work on characterisation of mechanical behaviour from microstructural features have been performed to identify important knowledge gaps. A simulation strategy has been formulated which is able to predict local mechanical behaviour throughout the entire component, and to incorporate this into a Finite Element Method (FEM) simulation of the structural behaviour of the component. In the simulation strategy, componentspecific microstructure-based mechanical behaviour is predicted using a casting process simulation. A computer program was developed to create FEM material definitions which capture the local variations in mechanical behaviour throughout the component. Using a material reduction technique, the local mechanical behaviour can be incorporated without increasing the FEM simulation time.

The relevance of the simulation strategy was experimentally verified on cast aluminium samples, where the strain field was observed using Digital Image Correlation (DIC). It was found that the local variations in mechanical behaviour cause a stress-strain distribution that deviates from that predicted by a homogeneous material description, indicating the importance of calculating with and including such variations in material behaviour in FEM simulations. Numerical investigations demonstrate the strategy’s relevance for predicting the behaviour of cast aluminium and ductile iron components.

Place, publisher, year, edition, pages
School of Engineering, Jönköping University, 2014. 51 p.
Series
JTH Dissertation Series, 3
Keyword
Component behaviour, structural analysis, mechanical behaviour, casting process simulation, Finite Element Method (FEM) simulation
National Category
Metallurgy and Metallic Materials Applied Mechanics
Identifiers
urn:nbn:se:hj:diva-23695 (URN)978-91-87289-04-0 (ISBN)
Public defence
2014-05-09, E1405, Tekniska Högskolan, Gjuterigatan 5, Jönköping, 10:00 (English)
Opponent
Supervisors
Available from: 2014-04-14 Created: 2014-04-11 Last updated: 2014-04-14Bibliographically approved

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