Optimized design processes by exploiting the full material performance: Computing local properties and residual stresses empowers engine casting development
Dr.-Ing. Götz Hartmann, MAGMA Aachen
Dr.-Ing. Ulrich Weiss, FORD Research & Advanced Engineering Europe
The properties of cast iron cylinder blocks are never uniform. In cast iron components, differences in wall thickness and other shape factors result in inhomogeneous cooling, solidification, microstructure, and properties throughout the casting. The same factors also produce residual stresses.
The experienced foundry man will have some ways to smooth out inhomogeneous microstructure and to moderate residual stresses, but often the effect is too small.
Standard CAE procedures for engine castings typically do not account for inhomogeneous properties and residual stresses, while advanced engine design optimization suffers increasingly from a mismatch between CAE durability prediction and test bed results in the context of ever increasing performance / weight ratios. These manufacturing process related characteristics need to be known and considered early in the design process.
The key to success is “Integrated Casting Process Simulation”. This technology allows to predict local properties and residual stresses and to feed them into the FE analysis and durability calculations.
Please read the complete publication in the linked PDF.