Numerical Simulation and Experimental Validation of Residual Stresses in Water-Quenched Aluminum Alloy Castings |
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Authors: | Bowang Xiao Keyu Li Qigui Wang Yiming Rong |
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Affiliation: | (1) Manufacturing Engineering, Worcester Polytechnic Institute, Worcester, MA 01609, USA;(2) Mechanical Engineering, Oakland University, 103 Dodge Hall, Rochester, MI 48309, USA;(3) Global Product Engineering, General Motors Company, Pontiac, MI 48340, USA |
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Abstract: | Aluminum alloy castings are normally water quenched after solution treatment to improve mechanical properties. Rapid water
quenching can result in high-residual stress and severe distortion which significantly affect functionality and performance
of the products. To optimize product design and durability, one needs to model and predict residual stress and distortion
produced in the water-quenched components. In this article, a finite element-based approach was developed to simulate the
transient heat transfer and residual stress development during water quenching. In this approach, an iterative zone-based
heat transfer algorithm was coupled with material constitutive model called mechanical threshold stress (MTS). With the integrated
models, a good agreement was achieved between the numerically predicted and the experimentally measured residual stresses
in the aluminum alloy frame-shape casting. The integrated FEA-based heat transfer and residual stress models were also applied
to a water-quenched cast aluminum cylinder head with a great success. |
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