Elasto-Plastic-Creep Constitutive Equation of an Al-Si-Cu High-Pressure Die Casting Alloy for Thermal Stress Analysis
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TRODUCTION
RESIDUAL stress and deformation in castings are crucially important issues not only for producing components having a highly precise shape but also for managing the life of casting components. Therefore, for the casting process, several researchers have tackled these problems using thermal stress analysis conducted via computer-aided engineering. The constitutive equation of the casting alloys strongly affects the predictive accuracy of residual stress and the deformation that occurs during casting. Therefore, accurate prediction demands selection of an appropriate constitutive equation and the use of mechanical properties of the casting alloy. Researchers have strived to measure the mechanical behaviors of casting alloys and to develop YUICHI MOTOYAMA, Researcher, is with the Department of Modern Mechanical Engineering, Waseda University, 3-4-1 Ookubo, Shinjuku-ku, Tokyo, 169-0072, Japan (now Advanced Manufacturing Research Institute, National Institute of Advanced Industrial Science and Technology, 1-2-1, Namiki, Tsukuba, Ibaraki, 305-8564, Japan). Contact email: [email protected] HIDETOSHI SHIGA and TAKESHI SATO, Engineers, and HIROSHI KAMBE, Expert Leader, are with the Powertrain Technology and Prototype Development Department, Nissan Motor Co. Ltd., 6-1, Daikokucho, Tsurumi-ku, Yokohama-shi, Kanagawa, 230-0053, Japan. MAKOTO YOSHIDA, Professor, is with the Kagami Memorial Research Institute for Material Science and Technology, Waseda University, 2-8-26, Nishiwaseda, Shinjuku-ku, Tokyo,169-0051, Japan. Manuscript submitted January 28, 2016. Article published online August 25, 2016 5598—VOLUME 47A, NOVEMBER 2016
constitutive equations for them from low to high temperature ranges. This study specifically examines the development of the constitutive equation of an Al-Si-Cu high-pressure die casting alloy [Japanese Industrial Standard (JIS) ADC12 (A383.0)]. The following sections respectively present discussion of earlier studies related to the mechanical properties of the Al-Si-Cu high-pressure die casting alloy and to constitutive equations for the casting process. A. Mechanical Properties Required for the Constitutive Equation Mechanical properties of Al-Si-Cu high-pressure die casting alloys have been measured from room temperature (RT) to the high temperature range. The obtained values have been used by several researchers for thermal stress analyses. Garza et al.[1] conducted elevated temperature tensile tests to ascertain the mechanical properties of the high-pressure die casting alloy A380.0 for computer prediction of the residual stress and of the casting distortion. Makhlouf et al.[2] obtained stress– strain curves of various high-pressure die casting alloys from RT to 473 K (200 C). However, their study did not measure stress–strain curves at temperatures higher than 473 K (200 C). Therefore, their material property data are insufficient to conduct accurate thermal stress analyses of the casting. Dong et al.[3] measured stress–strain curves of Al-Si-Cu aluminum high-pressure die casting allo
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