Sensitivity Tests of Simulation Models Used in Chosen Calculation Codes on Uncertainty of Thermo-Mechanical Parameters during Virtual Mechanical Stress Estimation for Ferrous Alloy Castings

Zenon Ignaszak; Paweł Popielarski

doi:10.4028/www.scientific.net/DDF.312-315.758

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HomeDefect and Diffusion ForumDefect and Diffusion Forum Vols. 312-315Sensitivity Tests of Simulation Models Used in...

Sensitivity Tests of Simulation Models Used in Chosen Calculation Codes on Uncertainty of Thermo-Mechanical Parameters during Virtual Mechanical Stress Estimation for Ferrous Alloy Castings

Abstract:

Simulation systems used for many years in foundry industry such as MAGMASOFT, NovaFlow&Solid and ProCAST, contain thermo-mechanical modules permitting the estimation of mechanical stresses and hot tears appearing in casting during its cooling. It is also known that these modules are rarely used because of the very limited thermo-mechanical database especially for ceramic materials such as foundry sand moulds. These technologies – castings pouring in non-permanent sand moulds, particularly iron alloys are most often applied in foundry. In our study the method of evaluating the algorithms quality applied in thermo-mechanical phenomena models based on parameters sensitivity testing from the proper database of the simulation system was used [1]. The comparative analyses of both experimental and virtual results were realized (by stress estimation). The methodology of experimental research was similar to that described where gray cast iron castings of stress bars (grid) were casted in sand mould bonded by organic resins.

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Periodical:

Defect and Diffusion Forum (Volumes 312-315)

Pages:

758-763

DOI:

https://doi.org/10.4028/www.scientific.net/DDF.312-315.758

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Online since:

April 2011

Authors:

Zenon Ignaszak, Paweł Popielarski

Keywords:

Casting-Mould Systems, Foundry Simulation Codes, Stress-Strain Modeling

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References

[1] Z. Ignaszak: Validation of simulating systems using for virtualization of manufacturing processes in cast iron foundry. Unpublished work, Poznan University of Technology, (2009).

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[2] Z. Ignaszak, P. Mikolajczak, P. Popielarski: Specificity and examples of on-line validation methods needed to predict the industrial castings quality by simulation systems (in Polish). Monograph Innovations in Foundry Industry,. Krakow 2009. ISBN 978-83-88770-45-6.

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[3] Z. Ignaszak, P. Popielarski: Defect and Diffusion Forum Vols. 283-286 (2009), p.376.

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[4] ProCAST User Manual, Version 2009. 1.

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[5] Nova Flow&Solid. Manual.

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[6] Magmasoft. Magmastress module. Stress simulation. Version 4. 2. User's Manual.

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