Towards optimization of stress simulation in real casting-mould systems

• Autorzy: Ignaszak Z.
• Języki publikacji: EN

Abstrakty

EN

The simulation codes using from many years by foundry industry such e.g. Magmasoft, NovaFlow&Solid and ProCast, contain also the thermo-mechanical modules permitting the estimation of mechanical stresses/deformations in casting during its cooling. It is also known that these modules are rarely used because of the very limited thermo-mechanical database especially for ceramic materials such as foundry sand mould. These technologies – castings pouring in non-permanent sand moulds, particularly iron alloys are most often applied in foundry. In our study the method of evaluating the algorithms quality applied in thermo-mechanical phenomena models based on parameters sensitivity testing from the proper database of the simulation system was used [1]. The comparative analyses of both experimental and virtual results were realized (by stress estimation). Methodology of experimental research was resemble to that described in provided that the applied gray cast iron casting of stress bars (grid) were casted in sand mould bonded by organic resins. Also the usefulness of author's method called Hot Distortion Plus® consisting in acquisition of temperature/distortion curves of heated sample of sand mould material and correlation with curves of their dilatation and also the inverse solution method are signalized as new proposition to estimate the chosen mechanical moulds parameters.

Słowa kluczowe

EN

foundry industry; information technology; cast iron castings; foundry simulation codes

PL

przemysł odlewniczy; technologie odlewnicze; naprężenia; odlewy żeliwne; modelowanie naprężeń

• Wydawca: Komisja Odlewnictwa Polskiej Akademii Nauk Oddział w Katowicach
• Czasopismo: Archives of Foundry Engineering
• Rocznik: 2010
• Tom: Vol. 10, iss. 4
• Strony: 69--76
• Opis fizyczny: Bibliogr. 18 poz., fot., rys., tab.

Twórcy

autor

Ignaszak Z.

• Poznań University of Technology, 3 Piotrowo Street, 60-965 Poznań, Poland.

Bibliografia

• [1] Z. Ignaszak: Validation of simulating systems using for virtualization of manufacturing processes in cast iron foundry. Unpublished work, Poznan University of Technology, 2009.
• [2] Z. Ignaszak, P. Mikolajczak, P. Popielarski: Specificity and examples of on-line validation methods needed to predict the industrial castings quality by simulation systems (in Polish). Monograph “Innovations in Foundry Industry”. Krakow 2009.
• [3] J. Mutwil, Design changes of device to investigation of alloys linear contraction and shrinkage stress. Archives of Foundry Engineering, 2009, Volume 9, Issue 4/2009, pp. 149 – 156.
• [4] W. Sakwa, Basic problems of stress in castings. Krzepniecie Metali i Stopow, vol. IV, 1981, pp.5–9 (in Polish).
• [5] R. Parkitny, Fundamentals of stress theory in castngs. Krzepniecie Metali i Stopow, vol. IV, 1981, pp.47–69 (in Polish).
• [6] G. Szwarc, N. Sczygiol , Analiza numeryczna stanu naprężenia w obszarze stało-ciekłym odlewu, Archives of Foundry, 2002, Volume 2, no 4, pp. 280-287.
• [7] Z. Ignaszak, P. Popielarski, Problem of the variability of substitute thermo-physical properties for heat transfer modelling in iso-exo sleeves used in foundry, Trans Tech Publications, Switzerland, Defect and Diffusion Forum Vols. 283-286 (2009), pp 376-381.
• [8] Nova Flow&Solid. Manual. Version 2.9-2r10.
• [9] ProCAST User Manual. Version 2009.1.
• [10] Magmasoft. Magmastress module. Stress simulation. Version 4.2. User’s Manual.
• [11] Z. Ignaszak, P. Popielarski, Sensitivity tests of simulation models used in chosen calculation codes on uncertainty of thermo-mechanical parameters during virtual mechanical stress estimation for ferrous alloy castings. Proceedings of VI Conference Diffusion in Solid and Liquid, Paris, 5-7.07.2010.
• [12] St. M. Dobosz, J. Jakubski, Hot-distortion – important crite-rion to core Sand quality estimation. Archiwum Technologii Maszyn i Automatyzacji vol. 21 nr 1 (2001), pp. 31–36 (in Polish).
• [13] St. M. Dobosz, J. Morek, DMA apparatus to i9nvestigate of high-temperature phenomena in core sands., Materiálové Inzinierstvo (Materials Engineering) Year 10 No 3 (2003), pp. 11–14 (in Czech).
• [14] Z. Ignaszak, Chosen aspects of thermo-mechanical phenome-na in resin bonded sands by use of Hot Distortion tests, Archives of Foundry Engineering, vol. 8, no. 1 (2008) pp.137 – 142.
• [15] Comsol, Comsol Structures Mechanics Module, Femlab 3.1 User’s Guide, Comsol AB, 2004.
• [16] Comsol, Comsol Multiphisycs 3.4 User’s Guide, Comsol AB, 2007.
• [17] Z. Ignaszak, P. Popielarski, T. Strek - Estimation of coupled thermo-physical and thermo-mechanical properties of porous thermolabile ceramic material using Hot Distortion Plus® test. Proceedings of VI Conference Diffusion in Solid and Liquid, Paris, 5-7.07.2010.
• [18] Z. Ignaszak , P. Popielarski. – Heat Transfer During Hot Distortion Test of Ceramic Porous Material Bonded by Various Resins, Trans Tech Publications, Switzerland, Defect and Diffusion Forum Vols. 283-286 (2009) pp 382-387.