Use of Casting Stress Simulation for Fatigue Simulation

Pouring Of Cast Irons

A Complex p Production Process
Flow Heat Transport Cooling Gases Convection Segregation Chemical Composition

Machining Solidification Stresses Heat Treatment Metallurgy Distortion

Content
How MAGMA supports you in the development of castings:
Optimized component development through

integration of process simulation Substitution into cast components - tools to define optimal component design

Optimized Component Development Object es Objectives

Reducing development time and costs through

improved virtual component design

Reliable assessment of fatigue life considering local

material behavior Exploitation of full material potential

Scrap p reduction through g early y integration g of

process simulation
Castable designs Early identification of potential problems

Robust quality / Improved reliability

The Integrated CAE Process for Castings

Reso ources

Integrated CAE process

- Simultaneous optimization p - Zero prototyping

Simultaneous optimization (component + process) Prototypes Integrated CAE procedure Verification Trial Time

Resources

Prototypes II Component optimization P t t Prototypes I P Process optimization ti i ti Trial Simulation Time

Conventional development process

- Hardware based - Sequential optimization

MAGMAmesh Finite Volume Mesh

The MAGMASOFT

mesh (Finite Volume Mesh)is shown in the pictures.

MAGMASOFT - Temperature Result

The temperature distribution

from MAGMASOFT at the end of solidification is shown.

MAGMAlink Input-Result Selection

The input and output formats are selected

in the marked window.

The results to be mapped

are selected in this window.

MAGMAlink Input and Output Format Variables

The INPUT formats available are:

ABAQUS UNIVERSAL PATRAN ANSYS PERMAS PAMCRASH RADIOSS STL CT-DATA

The OUTPUT formats available are:

ABAQUS IDEAS PATRAN ANSYS PERMAS PAMCRASH RADIOSS HYPERVIEW

Finite element mesh

The Finite Element Mesh

is shown in the pictures.

Mapped Results - Temperature

The MAGMASOFT results

(temperature distribution at the end of solidification) are mapped onto the FEM mesh.

Benefits of MAGMAlink #1
Improved Communication = Better Quality Sharing results with casting designers in their language Providing the designers with valuable information for

developing high performance, superior quality castings

Benefits of MAGMAlink #2
Provide a Premium Service with Little Extra Effort Competitive edge in developing stronger, better performing

castings
Minimal effort is required by the simulation engineer to

provide this information p

Examples
Impact of residual stresses on the safety factors for

engine design Impact of casting processes on life time of chassis components Impact of local component properties on the crash behavior of structural components

Residual Stresses in Crankcases

max 130 MPa max. min. -150 150 MPa

Impact of Residual Stresses on Fatigue Life

FSF = 1.3 13

FSF = 0.8 08

With t residual Without id l stresses t

With residual id l stresses t

Considering Thermal Residual Stresses caused by Design es g

Residual stresses can be harmful or useful! Residual stresses are a pre-load that need to be

integrated into durability calculation

Integrating information from process simulation

into FE-Analysis y allows an optimized p design g (higher performance, less weight)

Impact of Casting Processes on Life Time o C Chassis ass s Co Component po e t for

Prototype Sand casting : max. 13,200 load cycles

Series Permanent mold casting : max 43,300 max. 43 300 load cycles

Integration into Crash Simulation: Porosities for a B-Pillar

Courtesy of AUDI AG

Optimized Crash Simulation by Integration of oca p properties ope t es local

Experiment Simulation

Courtesy of AUDI AG

Summary of Advantages
Replacement of physical with virtual trials Lower design and planning costs Significantly lower development time Optimized machining parameters Improved process stability Higher production capacity

Development of Residual Stresses in a Cylinder Head due to T6-Heat T6 Heat Treatment

Description of the Manufacturing Process

Residual stresses during Heat Treatment

Solution Treatment (T<Ts):

At solution treatment temperatures all residual stresses caused by the casting process are relaxed due to creep.
Quenching

Due to inhomogeneous cooling, residual stresses develop.

Artificial Ageing (160C 200C)

Residual stresses are relaxed due to creep. The level of relaxation is about 30%, depending on ageing temperature and time.

Typical positioning of cylinder heads during T6 Heat Treatment Process

Quenching Basket

Definition of local, temperature dependent eat Transfer a s e Coe Coefficients c e ts ( (HTC) C) Heat
HTC outside HTC inside

Q
HTC-1

HTC

HTC-2

Surface temperature

HTC-4 HTC-3

Temperature distribution during quenching

Temperature distribution after 20s in a slice

T=310C T=120 C T=120C

High temperature differences during quenching will ill result lt i in hi high h residual id l stresses t

Stress development during Quenching

Relaxation of residual stresses due to artificial a t c a age ageing g

Influence of machining process on residual st esses stresses

Critical areas in cylinder heads

Validation of residual stress prediction

150 125 100 75 50 25 0 -150 -125 -100 -75 -50 -25 -25 -50 -75 -100 Cylinder Head 1 Cylinder y Head 2 0 25 50 75 100 125 150

M Messung

Simulation fits well -125 with measurements. The typical band width is about +/- 25 MPa and is -150 within the scatter of f the measurements. Simulation

Influence of residual stresses on HCF-Safety acto s Factors

Without Residual Stresses

Including Residual Stresses

Transfer of residual stresses on the FEes for o fatigue at gue life e prediction p ed ct o mesh
>100 MPa

Exhaust Fro ont End

Compression
-100 MPa

EX

0 MPa

+100 MPa

Intake

IN

Tension

Water Side View

>100 MPa

>100 MPa

Gas Side View

High-Cycle-Fatigue Safety Factors

HCF-Crack Initiation

Exhaust Port

EX Fron nt End

Durable
5.0 3.0 1.0

IN

Critical

Fron nt End

Critical !

Tangential Intake

Water Side View

Contact Info
Christof Heisser President MAGMA Foundry Technologies, Inc. 10 N. Martingale Road, Suite 425 Schaumburg, IL 60173 www.magmasoft.com cheisser@magmasoft.com 847-969-1001 Direct: 847-252-1650