Abstract
A method has been developed to predict stress development in gray iron foundry castings. A new yield function, based on theoretical developments by Frishmuth and McLaughlin,9 and on experiments by Coffin10 was implemented as a user-written element in a commercial finite element package. The yield function takes into account the strong dependence of the yield stress in cast irons on the loading path. Stresses resulting from thermal displacements in the cooling casting are computed using the new yield function in an elastic-viscoplastic stress analysis. In earlier work, techniques were developed to represent the mold in the thermal analysis by sets of boundary conditions on the surface of the part. For this work, a second user-written element was used to apply force-displacement boundary conditions on the surface of the casting to represent the mechanical constraint of the mold. The properties for this element were based on soil mechanics considerations. Example problems are given, showing a substantial difference in the computed stresses when using the present formulation, in comparison to results obtained with the more usual von Mises yield function.
Similar content being viewed by others
References
J.W. Wiese and J.A. Dantzig:Appl. Math. Modeling, 1988, vol. 12, pp. 213–20.
J.A. Dantzig and J.W. Wiese:Adv. Manufacturing Processes, 1986, vol. 1, pp. 437–54.
J.A. Dantzig and S.C. Lu:Metall. Trans. B, 1985, vol. 16B, pp. 195–202.
J.A. Dantzig and J.W. Wiese:Metall. Trans. B, 1985, vol. 16B, pp. 203–09.
A.F. Giamei and G.J. Abbaschian:4th Conf. of Modeling and Control of Casting and Welding Processes, TMS-AIME, Warrendale, PA, 1988.
C.F. Walton and T. J. Opar:Iron Castings Handbook, Iron Castings Society, Cleveland, OH, 1981, pp. 203–95.
G.J. DeSalvo and J.A. Swanson:ANSYS Engineering Analysis System User’s Manual, Volume I, Swanson Analysis Systems, Inc., Houston, PA, 1985, pp. 2.27.1–2.27.19.
G.J. DeSalvo and J.A. Swanson:ANSYS Engineering Analysis System User’s Manual, Volume I, Swanson Analysis Systems, Inc., Houston, PA, 1985, pp. 4.7.1–4.7.6.
R.E. Frishmuth and P.V. McLaughlin:J. Mater. Technol., 1976, vol. 98, pp. 69–75.
J.L.F. Coffin:J. Appl. Mech., 1950, vol. 17, pp. 233–48.
D.C. Drucker:1st U.S. Congress of Applied Mechanics, 1952, vol. 1, pp. 487–91.
R.D. Pehlke, A. Jeyarajan, and H. Wada:Summary of Thermal Properties for Casting Alloys and Mold Materials, NTIS-PB83-211003, University of Michigan, Ann Arbor, MI, 1982.
M.R. Ozgu:Thinner Walled Ingot Molds: Mathematical Modeling of Thermal Stresses and Plant Trials With Lighter Big-End-Up Molds, Inland Steel Presentation, E. Chicago, IN, 1983.
G.J. DeSalvo and J.A. Swanson:ANSYS Engineering Analysis System User’s Manual, Volume I, Swanson Analysis Systems, Inc., Houston, PA, 1985, p. 8.4.
R.W. Heine, C.R. Loper, and P.C. Rosenthal:Principles of Metal Casting, McGraw-Hill, New York, NY, 1967, pp. 84–122.
H. Tresca:Compt. Rend., 1864, vol. 59, p. 754.
Author information
Authors and Affiliations
Additional information
Formerly at the University of Illinois.
Rights and permissions
About this article
Cite this article
Wiese, J.W., Dantzig, J.A. Modeling stress development during the solidification of gray iron castings. Metall Trans A 21, 489–497 (1990). https://doi.org/10.1007/BF02782429
Received:
Issue Date:
DOI: https://doi.org/10.1007/BF02782429