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Characterisation and investigation of local variations in mechanical behaviour in cast aluminium using gradient solidification, Digital Image Correlation and finite element simulation
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.
Department MTM, KU Leuven, Belgium.
Department MTM, KU Leuven, Belgium.
2014 (English)In: Materials & Design, ISSN 0261-3069, Vol. 56, 755-762 p.Article in journal (Refereed) Published
Abstract [en]

Due to design and process-related factors, there are local variations in the microstructure and mechanical behaviour of cast components. This work establishes a Digital Image Correlation (DIC) based method for characterisation and investigation of the effects of such local variations on the behaviour of a high pressure, die cast (HPDC) aluminium alloy. Plastic behaviour is studied using gradient solidified samples and characterisation models for the parameters of the Hollomon equation are developed, based on microstructural refinement. Samples with controlled microstructural variations are produced and the observed DIC strain field is compared with Finite Element Method (FEM) simulation results. The results show that the DIC based method can be applied to characterise local mechanical behaviour with high accuracy. The microstructural variations are observed to cause a redistribution of strain during tensile loading. This redistribution of strain can be predicted in the FEM simulation by incorporating local mechanical behaviour using the developed characterization model. A homogeneous FEM simulation is unable to predict the observed behaviour. The results motivate the application of a previously proposed simulation strategy, which is able to predict and incorporate local variations in mechanical behaviour into FEM simulations already in the design process for cast components.

Place, publisher, year, edition, pages
Elsevier, 2014. Vol. 56, 755-762 p.
Keyword [en]
Casting, Component behaviour, Mechanical behaviour, Aluminium, Digital Image Correlation, Plastic behaviour
Keyword [sv]
Gjutning, Komponent beteende, Mekaniskt beteende, Aluminium, Digital Image Correlation, Plastiskt beteende.
National Category
Materials Engineering Applied Mechanics Metallurgy and Metallic Materials
Identifiers
URN: urn:nbn:se:hj:diva-22802DOI: 10.1016/j.matdes.2013.12.036ISI: 000331721100096Scopus ID: 2-s2.0-84890830495Local ID: JTHMaterialISOAI: oai:DiVA.org:hj-22802DiVA: diva2:680982
Available from: 2013-12-19 Created: 2013-12-18 Last updated: 2017-08-14Bibliographically approved
In thesis
1. 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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