Abstract
In general, thermal residual stress is generated in casting products as a result of non-uniform cooling, phase transformation from liquid to solid states, and thermo-mechanical constraints. Thus, understanding accurate stress distributions is important in designing a casting part to predict its real structural stability. However, the residual stress that occurs in the casting process is often not considered in the mechanical design process to reduce engineering efforts and time. We conducted a structural analysis that compares two cases with and without considering casting residual stress in large-scale sand castings and obtained significantly different results. We introduced an interfacing algorithm (casting-structural interface) to map the casting residual stress with structural stress and combined the results of finite different analysis for casting and finite element analysis for structural design. This work represents our preliminary studies on improving the design accuracy of a large-scale casting part and shows the importance of considering the casting residual stress. A difference of about 41% in maximal principle stress is obtained with and without considering the casting residual stress.
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Jae Hyun Yu is finishing his Ph.D. at Pusan National University. He received his M.A. (2011) in Mechanical Engineering from Pusan National University. His current research interests are Casting Structure Interface method in casting analysis.
Zhi jun Zhao is currently finishing his Ph.D. at Pusan National University. He received his M.A. (2014) in Mechanical Engineering from Kumoh National Institute of Technology. His current research interests are Micro-Scale Wrinkles and 3D Printing.
Changmin Son is a professor of mechanical engineering at Pusan Nation University. He earned his B.A. and M.A. at Pusan National University (Korea) in 1989 and 1991, respectively. He earned his Ph.D. at the University of Oxford (England) in 2005. He has worked on gas turbine heat transfer and aerodynamics.
Sang Hu Park is a professor of mechanical engineering at Pusan National University. He earned his M.S. and Ph.D. in mechanical engineering at Korea Advanced Institute of Science and Technology (KAIST, Korea) in 1996 and 2006, respectively. His research fields are the development of 3D printing process, mechanical design, and manufacturing technology, especially for multi-scale structures.
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Yu, J.H., Zhao, Z.j., Son, C. et al. Improvement of structural design accuracy using a casting-structural interface (CSI) method in large-scale sand castings. J Mech Sci Technol 29, 5093–5098 (2015). https://doi.org/10.1007/s12206-015-1106-x
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DOI: https://doi.org/10.1007/s12206-015-1106-x