Residual Stress Numerical Simulation Of Engine Cylinder Block

The specific research object was cylinder block casting of a foundry in this article, the numerical simulation of temperature field and stress field during the solidification of cylinder block casting was carried out by the professional casting simulation software—ProCAST, with three different pouring temperatures and three different shakeout temperatures, respectively. The residual stress distribution, strain distribution and change information of stress and strain during the cooling process were obtained. The influence of pouring temperature and shakeout temperature on the temperature field distribution, cooling velocity, stress and strain was analyzed.The whole of numerical simulation was divided into mold filling simulation, stress simulation before shakeout and stress simulation after shakeout three parts, according to the feature of ProCAST, content of numerical simulation and hardware condition of computer. This research used the symmetry plane, the unidirectional coupling method of the temperature file and the stress file and considers the interaction relationship between casting and mold in simulation calculation.Through analysis the result of numerical simulation, we could drawn the influence of pouring temperature on the temperature field distribution and cooling velocity, the cooling velocity of casting in the mold was decreased along with the elevation of the pouring temperature, but that was increased after shakeout. Meanwhile, the changing law of casting's stress and strain could obtain. The Von Mises stress first almost unchanged and then decreases after the temperature was over 1410 o C along with the elevation of the pouring temperature before shakeout, the higher is the pouring temperature, the smaller is the residual stress after shakeout. The higher is the shakeout temperature, the smaller is the Von Mises stress when at shakeout time, but the bigger is the residual stress at finally. Under the condition of the same pouring temperature, The higher is the shakeout temperature, the smaller is the displacement value when at shakeout time, but the bigger is the residual strain at finally. The higher is the pouring temperature, the bigger is the displacement value just at time of want to shakeout, when the shakeout temperature is equivalent. But, the influence of pouring temperature on the final residual strain does not have any rule.This article achieved the numerical simulation of cylinder block casting under different process parameters on the ProCAST software platform. Provided a new improvement and optimization technology means to replace the traditional"trial and error"method for process designers, thus reducing the cost of production. Therefore this research has an important theoretical significance and superior practical engineering value.