Verification of the Simulated Residual Stress in the Cross Section of Gray Cast Iron Stress Lattice Shape Casting via Th
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THE control of the residual stress and the deformation of the castings that occurs during cooling is the key for managing the fatigue life of the casting and for producing the near-net-shape casting. Computer-aided engineering (CAE) should be a powerful tool for studying these issues. Thus, several researchers have attempted to predict the residual stress and the deformation of castings using the thermal stress analysis via CAE.[1–14] For the evaluation of the residual stress, the stress lattice shape casting (hereinafter referred to as ‘‘stress lattice’’) was used in the previous studies. The YUICHI MOTOYAMA, formerly Doctoral Student with the Department of Modern Mechanical Engineering, Graduate School of Waseda University, 3-4-1 Okubo, Shinjuku-ku, Tokyo 169-8555, Japan, is now Assistant Professor with the Research Center for Advanced Science and Technology (RCAST), The University of Tokyo, Japan. Contact e-mail: [email protected] DAIKI INUKAI, Student, is with the Department of Modern Mechanical Engineering, Graduate School of Waseda University. 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. 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, Shinjuku-ku, Tokyo 169-0051, Japan. Manuscript submitted July 20, 2013. Article published online December 7, 2013 METALLURGICAL AND MATERIALS TRANSACTIONS A
stress lattice is composed of a thick part and thin part of which both ends are attached with rigid casting parts. The residual stress occurring at the thick part is composed of two sources.[8] One is the tensile residual stress due to the temperature difference between the thick part and the thin part (hereinafter referred to as residual stress ). This residual stress develops uniformly in the cross section of the thick part. The other is the residual stress due to the temperature difference in the cross section of the thick part (hereinafter referred to as residual stress `). Residual stress ` exhibits a stress gradient in the radial direction in the cross section of the thick part because the residual stress is balanced in its cross section. There are several studies that performed thermal stress analysis to predict the residual stress of the stress lattice. We review these studies in the following, except for those studies that did not compare a simulation with the experimental results. Yoshizawa and Wang[9] cast a stress lattice made of cast steel and simulated the residual stress of its casting. However, only residual stress was compared with the measurement. Gustaffson et al.[10] cast a gray cast iron stress lattice and conducted a thermal stress analysis based on the experimental results. They compared the predicted residual stress with the experimental measure
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