In Situ Measurement and Prediction of Stresses and Strains During Casting of Steel

Prediction of distortions and pattern allowances in steel sand castings

“…Temperatures are calculated first using casting simulation software and then inputted into a finite element stress analysis. The steel is modeled using an elastovisco-plastic constitutive law, whose parameters were calibrated in a previous study [13].…”

“…This strategy allows for a single robust constitutive relation capable of modeling the steel in the liquid, semi-solid, and solid phases. A detailed description of the model and mechanical properties is given by Galles and Beckermann [13]. For the elastic mechanical properties, Young's modulus for the steel was taken from Li and Thomas [23] and is shown in and Beckermann [13] and is shown in Figure 4.3.…”

“…The predicted thermal strains for the cylinder are compared with the silica and zircon LVDT measurements on complete and 600 s time scales in Figure 5.1(a) and (b), respectively. Thermal strains were calculated using the linear thermal expansion of steel (shown in Figure 4.3), which was calibrated in a previous study [13]. During the initial 250 s, the simulation does not predict any change in the inner diameter, as the onset of thermal contraction for the steel does not begin until shortly before complete solidification (denoted by a vertical dashed line in Figure 5.1(b)).…”

“…At 250 s, the thermal strain simulation curve begins to decrease, as the steel has reached coherency and begins to thermally contract. The onset of thermal contraction was set to a solid fraction of g s = 0.97 [13]. After complete solidification of the cylinder (at approximately 325 s), the thermal simulation curve decreases at the same rate as the silica and zircon LVDT measurements.…”

“…A constant value of 0.3 was taken for Poisson's ratio. Parameters for the dynamic yield equation[13] are shown in…”