Numerical and Experimental Study on Residual Stress in Gray Cast Iron Stress Lattice Shape Casting

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RESIDUAL stresses and distortions are serious problems in the fabrication of castings. Therefore, various studies have been conducted to address these issues using stress lattice shape castings (stress lattice). In the current study, the following issues related to the residual stress in the stress lattice were studied: YUICHI MOTOYAMA, Student, is with the Department of Modern Mechanical Engineering, Graduate School of Waseda University, 3-4-1 Shinjyuku-ku, Okubo, Tokyo 169-8555, Japan. Contact e-mail: [email protected] HIROKI TAKAHASHI, formerly Student with the Department of Modern Mechanical Engineering, Graduate School of Wased University, is now Regular Member with the Package Group, Future Module Development Center, Electronic Device Laboratory, Corporate R&D Headquarters, Fuji Electric Co., Ltd., Matsumoto, Nagano, Japan. TOSHIMITSU OKANE, Leader, is with the Advanced Manufacturing Research Institute, National Institute of Advanced Industrial Science and Technology (AIST), 1-2-1 Namiki, Tsukuba, Ibaraki 305-8564, Japan. YOYA FUKUDA, General Manager Research, is with the Development Department, Kimura Chuzosho Co., Ltd., 1157 Nagasawa, Shimizu-cho, Sunto-gun, Shizuoka-ken, Japan. MAKOTO YOSHIDA, Professor, is with the Department of Modern Mechanical Engineering, Graduate School of Waseda University, and also with the Kagami Memorial Laboratory for Materials Science and Technology, Waseda University, 2-8-26, Nishi-Waseda, Shinjyuku-ku, Tokyo 169-0051, Japan. Manuscript submitted June 19, 2012. Article published online March 13, 2013 METALLURGICAL AND MATERIALS TRANSACTIONS A

(a) The effect of the shake-out temperature on the residual stress in a stress lattice. (b) Verification of the thermal stress analysis to predict the residual stress in the stress lattice. Figure 1(a) shows an example of the stress lattice. The stress lattice is composed of thick and thin parts, where both ends are attached with the rigid casting parts. After cooling, the thick part is under tensile residual stress, whereas the thin part experiences compressive stress with bending. The residual stress occurring in the thick part is composed of the residual stress due to the temperature difference  between the thick part and the thin part and ` in the cross section of the thick part. However, the residual stress due to  has been regarded, as almost all of the residual stress occurring in the thick part, and the residual stress ` has been ignored in previous studies.[1] Therefore, the current study also simply calls the residual stress  ‘‘the residual stress’’ at the thick part. With the stress lattices, previous studies have investigated the effect of casting conditions on the residual stress. The casting conditions that affect the residual stress are as follows: differences in the cooling rate, the strength of the sand mold, the amount of water in the sand mold,[2,3] the chemical compositions of the casting alloy,[4] and the shake-out temperature.[2,5] From the viewpoint of the productivity, the effect of the shake-out temperature on th

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