Thermal stress simulation is an important part in the numerical simulation of casting process. It provides engineers with insights into the evolution of displacement, strain and stress of castings in the solidification process. With thermal stress simulation, some defects of casting, i.e. hot tearing, cold cracking and large deformation can be predicted and the engineers are instructed to optimize and improve the casting process. Based on the finite difference method (FDM), this paper presents an integrated numerical method to simulate the thermal stress and deformation of casting in the solidification process. Practical examples show that the method is capable to predict stress distribution and deformation as well as the defects in the experiment.

methods

Using finite difference method to simulate casting thermal stress

Numerical Simulation of Casting Thermal Stress and Deformation Based on Finite Difference Method

Deformation of casting during the solidification process has puzzled many engineers and scientists for years. In order to attain the goal of near-net forming by casting, numerical simulation is a powerful tool. Traditional methods compute the thermal stress of both the casting and the mold. This method suffers the problem of massive calculation and failure of convergence. This paper proposes an improved Mold Surface Element Method, the main idea of which is to use the surface elements instead of body elements to express the interactions between the casting and the mold. The proposed method shows a high computation efficiency and provides satisfactory precision for engineering. Two practical casting products were used to verify the proposed method. The simulated results agree well with those observed in practical products. The proposed method is believed to benefit production practice and to provide theoretical guidance.

/pdf/simulation-of-casting-deformation-based-on-mold-surface-1ialqkxei9.pdf

Simulation of casting deformation based on mold surface element method

With the development and wide application of extradosed cable stayed bridge, an effective method is needed for simulation of the stress distribution in anchorage zone, which plays a vital role in transferring force from the cable to the pylon and diverting the cable direction. Based on the Finite Difference Method (FDM), an efficient and practical method of stress filed simulation was presented in the paper. First, a plane finite element model was established using ABAQUS, to determine the boundary condition for FDM. Based on this, FDM was used to simulate the stress distribution of the concrete in the anchorage zone. Finally, on the simulation result was calculated and in comparison with finite element model result. It has been found that: The vertical compressive stress of concrete in the anchorage zone gradually reduces from the middle to the two sides, and the stress assumes double peak type in transverse. Compared with the finite element solutions, the approximate solution simulated by FDM improve the computational efficiency with certain accuracy keeping, except the loading area. In vertical orientation, the concrete in the place of H (the width of the pylon) from cable force acting position is in a state of uniform stress.

/pdf/finite-difference-method-in-stress-analysis-of-anchorage-1druh91ulq.pdf

Using finite difference method to simulate casting thermal stress

Citations

Numerical Simulation of Casting Thermal Stress and Deformation Based on Finite Difference Method

Simulation of casting deformation based on mold surface element method

Finite Difference Method in Stress Analysis of Anchorage Zone of Highway Extradosed Cable Stayed Bridge

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