Thermal Stresses in a Cylinder Block Casting Due to Coupled Thermal and Mechanical Effects

Thermal stress in castings results from nonuniform cooling. The thermal stress and the deformation can change the casting and mold contact conditions which then alter the heat transfer between the casting and the mold. The contact element method was used to study the interaction between a sand mold and a casting. The contact status was then fed back to the heat transfer analysis between the sand mold and the casting to re-evaluate the heat transfer coefficient based on the gap size or pressure between surfaces. The thermal and mechanical phenomena are then coupled in two directions. The method was applied to analyze stress in a stress frame specimen casting and a cylinder block. The results are more accurate than without consideration of the contact effects on the heat transfer.     

消失模珠粒射料充填过程的数值模拟

为了解消失模珠粒射料充填过程,采用Eulerian-Lagrangian方法建立了数学模型,并进行了数值模拟。在该模型中把空气处理成连续介质,采用SIMPLE方法在Euler网格中求解气相连续方程和动量方程;珠粒为离散颗粒,其运动遵循Newton运动定律。采用自行设计的模具进行了实验验证,用数码摄像机记录了珠粒充填过程。数值模拟和实验结果显示:在珠粒充填前期,模具底部空气流动速度快,携带能力强,到达模具底部的珠粒都被带到顶部堆积。珠粒充填超过2/3以后,珠粒才开始在底部堆积,最后形成一个椭圆形漩涡并逐步消失。数值模拟和实验结果符合较好。