Simulation of Stress Distribution in a Thick- Walled Bushing Produced by Die-Casting

Open access

Abstract

Metallographic investigations and a computer simulation of stresses in a gravity die-casting bushing were performed. Simulation of the casting process, solidification of the thick-walled bushing and calculations of the stress was performed using MAGMA5.3 software. The size variability of phases κII affecting the formation of phase stresses σf, depending on the location of the metallographic test area, was identified. The distribution of thermal σt and shrinkage stresses σs, depending on the location of the control point SC in the bushing's volume, was estimated. Probably the nature of these stresses will change slightly even after machining. This can cause variations in operating characteristics (friction coefficient, wear). Due to the strong inhomogeneity of the stress distribution in the bushing's casting, it is necessary to perform further tests of the possibility to conduct thermal treatment guaranteeing homogenization of the internal stresses in the casting, as well as to introduce changes in the bushing' s construction and the casting technology. The paper presents the continuation of the results of research aimed at identifying the causes of defects in the thick-walled bushing, die-casting made of CuAl10Fe5Ni5Cr aluminium bronze.

[1] Kaschnitz, E., Heugenhauser, S. & Schumacher, P. (2015). A benchmark for the validation of solidification modelling algorithms, Materials Science and Engineering. 84, 1-7. DOI: 10.1088/1757-899X/84/1/012051

[2] Isfahani, A.H.G. & Brethour, J.M. (2012). Simulating Thermal Stresses and Cooling Deformations. Die Casting Engineer. March, 34-36.

[3] Xue, X. Wang, Y. P. (2013) Numerical Simulation of Casting Thermal Stress Based on Finite Difference Method. Rev. Adv. Mater. Sci. 33, 410-415.

[4] Gwiżdż, A., Żuczek, R. & Nowak, M. (2012). Analysis of the State of Stress in Cast Bodies, Covers and Wedges of the Wedge Gate Valves Used in Gas Networks. Transactions of Foundry Research Institute. Volume LII, Number 4, 300-325. DOI: 10.7356/iod.2012.23

[5] Senczyk, D., Moryksiewicz, S. (February 12, 2017). Treatments - concepts and classification. senczyk_naprezenia_wlasne.pdf. Retrieved June 06, 2017, from http://www.badania-nieniszczace.info/Badania-Nieniszczace-Nr-01-03-2007/pdf/senczyk_naprezenia_wlasne.pdf. (in Polish).

[6] Sakwa, W. (1981). Basic problems of stress in castings. Krzepnięcie Metali i Stopów. 4, 5-9. (in Polish).

[7] Pisarek, B.P., Kołakowski, D. & Pacyniak, T. (2016). Analysis of the Causes of Cracks in a Thick-Walled Bush Made of Die-Cast Aluminum Bronze. Archives of Foundry Engineering. 16(4), 119-124.

Archives of Foundry Engineering

The Journal of Polish Academy of Sciences

Journal Information


CiteScore 2016: 0.42

SCImago Journal Rank (SJR) 2016: 0.192
Source Normalized Impact per Paper (SNIP) 2016: 0.316

Metrics

All Time Past Year Past 30 Days
Abstract Views 0 0 0
Full Text Views 160 160 12
PDF Downloads 77 77 8