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Effect of Sand Mold Constraint on Warpage Deformation of Lamellar Graphite Gray Cast Iron and Prediction by Elastoplastic-Creep Finite Element Analysis

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Abstract

Casting that comprises multiple parts with different thicknesses is prone to experience warpage deformation due to the non-uniform temperature distribution from the beginning of solidification to room temperature. This study is the first to investigate the effect of sand mold shake-out timing on the warpage deformation of a lamellar graphite gray cast iron casting with thick and thin geometries by both experiment and finite element analysis. It was found that warpage deformation was suppressed by 81.6% when the shakeout was performed just after A1 (austenite to ferrite) phase transformation temperature rather than after eutectic solidification temperature. The elastoplastic-creep analysis was proven to predict the warpage amount better than elastoplastic analysis, in which prediction error was reduced by 116%. The introduction of creep term that should not contribute to the work-hardening of the casting was assumed to relax the stress and suppress the warpage deformation; however, poor estimation of the creep properties at about 1000 °C to the A1 transformation temperature reduced the prediction accuracy. A sudden increase of warpage was observed and predicted during shakeout due to the release of the elastic strain that was accumulated as a result of sand mold constraint.

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Acknowledgments

The authors would like to express gratitude to Mr. Akihiro Yano for the assistance during experiment. This research did not receive any specific grant from funding agencies in the public, commercial, or not-for-profit sectors.

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Author notes

  1. Kengo Uehara

    Present address: The Japan Research Institute, 2-10-2 Higashi Gotanda, Shinagawa-ku, Tokyo, 141-0022, Japan

  2. Tomoki Nakajima

    Present address: Lombard Inc., A-PLACE Gotanda Ekimae, 1-5-1 Nishi Gotanda, Shinagawa-ku, Tokyo, 141-0031, Japan

Authors and Affiliations

  1. Kagami Memorial Research Institute for Materials Science and Technology, Waseda University, 2-8-26 Nishi Waseda, Shinjuku-ku, Tokyo, 169-0051, Japan

    Muhammad Khairi Faiz & Makoto Yoshida

  2. Department of Mechanical Engineering, Graduate School of Creative Science and Engineering, Waseda University, 3-4-1 Okubo, Shinjuku-ku, Tokyo, 169-8555, Japan

    Kengo Uehara & Tomoki Nakajima

  3. Kimura Foundry Co., Ltd., 1157 Nagasawa, Shimizu, Sunto-gun, Shizuoka, 411-0905, Japan

    Toshitake Kanno & Yuichi Hiramoto

  4. Department of Mechanical Engineering, School of Creative Science and Engineering, Waseda University, 3-4-1 Okubo, Shinjuku-ku, Tokyo, 169-8555, Japan

    Tomoyuki Miyashita & Makoto Yoshida

  5. Advanced Manufacturing Research Institute, National Institute of Advanced Industrial Science and Technology, 1-2-3 Namiki, Tsukuba, Ibaraki, 305-8564, Japan

    Toshimitsu Okane

Authors
  1. Muhammad Khairi Faiz
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  2. Kengo Uehara
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  4. Toshitake Kanno
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  5. Yuichi Hiramoto
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  6. Tomoyuki Miyashita
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  7. Toshimitsu Okane
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  8. Makoto Yoshida
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Correspondence to Muhammad Khairi Faiz.

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Khairi Faiz, M., Uehara, K., Nakajima, T. et al. Effect of Sand Mold Constraint on Warpage Deformation of Lamellar Graphite Gray Cast Iron and Prediction by Elastoplastic-Creep Finite Element Analysis. J. of Materi Eng and Perform 30, 4669–4680 (2021). https://doi.org/10.1007/s11665-021-05716-1

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  • DOI: https://doi.org/10.1007/s11665-021-05716-1

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