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Meeting 2016 TMS Annual Meeting & Exhibition
Symposium Shape Casting: 6th International Symposium
Presentation Title Modeling of Distortion of a Steel Bracket Sand Casting
Author(s) Daniel Galles, Christoph Beckermann
On-Site Speaker (Planned) Daniel Galles
Abstract Scope Modeling the thermo-mechanical behavior of bonded sand is essential for predicting casting distortions. In this study, steel casting experiments involving a U shaped bracket are performed to investigate the effect of core restraint. The gap opening between the bracket legs is measured in-situ using LVDTs (Linear Variable Differential Transformers) that are attached to quartz rods embedded into the bottom of each leg. During cooling, the core restrains the thermal contractions of the steel and pushes the legs outward, generating distortions. To simulate the experiments, calculated transient temperature fields are input into a finite element stress analysis code. The steel is modeled using an elasto-visco-plastic constitutive law, while the core employs the Drucker Prager Cap model. After adjustments to the high-temperature core sand properties, the observed distortions are accurately predicted.
Proceedings Inclusion? Planned: A print-only volume

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Coupled Thermal-stress Model of A319 Alloy Chilled Sand Casting
Analytical Model of Filling Fine Features and Sharp Corners in Investment Casting of CMSX-4
Bifilms and Hot Tearing of Al-Si Alloys
Change in Si Morphology with Time and Temperature in Sr Modified A356
Characterization of Tensile Deformation in AZ91D Mg Alloy Castings
Crack Susceptibility of Binary Aluminum Alloys: Analytical Equations
Effect of Duration on Ti Grain Refinement of A356 and Melt Quality
Effects of Casting Conditions on End Product Defects in Direct Chill Casted Hot Rolling Ingots
Effects of Sr on the Microstructure of Electromagnetically Stirred Semi Solid Hypoeutectic Al-Si Alloys
Evolution of Primary Fe-rich Compounds in Secondary Al-Si-Cu Alloys
Grain Refinement of Al-Si Hypoeutectic Alloys by Al3Ti1B Master Alloy and Ultrasonic Treatment
Influence of Process Parameters on the Microstructure and Casting Defects of a LPDC Engine Block
Methods of Reducing Materials’ Waste and Saving Energy in Investment Casting
Modeling of Distortion of a Steel Bracket Sand Casting
On The Mean Stress Correction in Fatigue Life Assessment in Cast Aluminum Alloys
On the Properties and Performance of Ablation Cast Components
On the Relationship between Quality Index, Fatigue Life and Fracture Toughness Distributions in D357 and B201 Alloy Castings
Preliminary Investigation of the Grain Refinement Mechanism in Cu Alloys
Quality Assessment of A356 Ingots from Different Suppliers in Wheel Production
Real-time Radiography and Modeling of Porosity Formation in an A356 Aluminum Alloy Wedge Casting
SiC Particle Reinforced Al Matrix Composite by SIMA
Solidification Analysis of Magnesium Alloys Using In-situ Neutron Diffraction
The Reliability of Ductile Iron Casting Dependent on Runner System Design: An Example of Support Bracket of Brake Caliper

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