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Robustness of residual stresses in castings and an improved process window
Tekniska Högskolan, Högskolan i Jönköping, JTH, Maskinteknik.
Tekniska Högskolan, Högskolan i Jönköping, JTH, Maskinteknik.
2009 (English)In: Proceedings of the 35th Design Automation Conference, August 30-September 2, San Diego, USA 2009, 2009Conference paper, Published paper (Refereed)
Abstract [en]

In this work the robustness of residual stresses in finite element simulations with respect to deviations in mechanical parameters in castings is evaluated. Young's modulus, the thermal expansion coefficient and the hardening are the studied parameters. A 2D finite element model of a stress lattice is used. The robustness is evaluated by comparing purely finite element based Monte Carlo simulations and Monte Carlo simulations based on linear and quadratic response surfaces. Young's modulus, the thermal expansion coefficient and the hardening are assumed to be normal distributed with a standard deviation that is 10% of their nominal value at different temperatures. In this work an improved process window is also suggested to show the robustness graphically. By using this window it is concluded that least robustness is obtained for high hardening values in combination to deviations in Young's modulus and the thermal expansion coefficient. It is also concluded that quadratic response surface based Monte Carlo simulations substitute finite element based Monte Carlo simulations satisfactory. Furthermore, the standard deviation of the responses are evaluated analytically by using the Gauss formula, and are compared to results from Monte Carlo simulations. The analytical solutions are accurate as long as the Gauss formula is not utilized close to a stationary point.

Place, publisher, year, edition, pages
2009.
Keyword [en]
Robustness, Finite element method, Monte Carlo, Response surface, Casting, Process window
National Category
Mechanical Engineering
Identifiers
URN: urn:nbn:se:liu:diva-72349OAI: oai:DiVA.org:liu-72349DiVA: diva2:459247
Conference
The 35th Design Automation Conference, August 30-September 2, San Diego, USA
Projects
MERA
Available from: 2009-06-15 Created: 2011-11-25 Last updated: 2011-11-25Bibliographically approved
In thesis
1. Robustness Analysis of Residual Stresses in Castings
Open this publication in new window or tab >>Robustness Analysis of Residual Stresses in Castings
2012 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

This thesis is about robustness analysis of residual stresses in castings. This topic includes the analysis of residual stresses in castings and the robustness analysis itself, both covered in the thesis.

Residual stresses are important when designing casted components. For instance, the residual stress state after casting might affect the fatigue life, facilitate crack propagation and cause spring-back related problems when a casted component is machined or used. Examples of components where such problems are recognized are stamping dies and brake discs, both considered in the thesis. Residual stresses in castings are simulated by finite element analysis in this thesis. A sequential un-coupled approach is used where a thermal analysis of the solidification and cooling generates a temperature history. Then a quasi-static structural analysis is performed, driven by the temperature history. During the structural analysis residual stresses are developed due to different cooling rates in combination with plasticity. For comparison, measurements of residual stresses in castings have also been performed. The agreement between analyses and measurements is satisfactory.

In a residual stress analysis there are several random variables such as process, geometrical and material parameters. Usually those random variables are assumed to be deterministic and their nominal values are used. It can be beneficial to include the variation of the random variables in analysis of residual stresses. For that purpose robustness analysis of the residual stresses are performed in this thesis. In some of the appended papers the robustness is evaluated with respect to variation in e.g. Young’s modulus, yield strength and hardening, thermal expansion coefficient, geometric dimensions and time in mould of the casting. The robustness analyses are performed by using metamodels as surrogates to the finite element model, due to the computational expensiveness of the residual stress analyses. Conventional regression models, Kriging approximations and an optimal polynomial regression model, proposed in one of the appended papers, are metamodels used in the thesis. When a metamodel is established the choice of the design of experiments can be crucial. The generation of the design of experiments is also investigated in the thesis. For instance, a hybrid method constituted by a genetic algorithm and sequential linear programming is proposed for the generation of optimal design of experiments. A-, D-, I- and S-optimal design of experiments are generated by the developed  hybrid method. Those design of experiments as well as Latin  Hypercube sampled design of experiments are used throughout the thesis. Since residual stress analysis, robustness analysis and metamodeling are considered in the thesis, more or less all parts required to perform robustness analysis of residual stresses in castings are covered.

Results in the thesis show that the level of residual stresses in castings can be high due to the casting process. Thus, crack development and spring-back related problems might be influenced by those stresses. Results also show that the level of residual stresses can be very dependent on the variation in certain random variables such as the thickness of the casting, hardening and Young’s modulus. Therefore, it can be of importance to include the variations of the random variables in order to accurately predict the residual stresses when designing castings.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2012. 44 p.
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1415
National Category
Engineering and Technology
Identifiers
urn:nbn:se:liu:diva-72354 (URN)978-91-7393-002-4 (ISBN)
Public defence
2012-01-20, E1405, Tekniska högskolan, Jönköping, 10:00 (Swedish)
Opponent
Supervisors
Available from: 2011-11-25 Created: 2011-11-25 Last updated: 2012-04-02Bibliographically approved

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Hofwing, MagnusStrömberg, Niclas

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