(Received 1 October 2011; accepted 29 March 2012)
Published Online: 2012
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A method for quantifying distortions arising in engine blocks of aluminum with liners of gray iron has been developed based on virtual finite element-based simulation tools. The key processing steps comprise the convection cooling step, associated with shrinkage and residual stress build-up, and the machining step. The engine block has been modeled using the finite element method and machining has been simulated using the element-removal technique. The mechanical behavior of aluminum has been characterized by tensile tests at different temperatures and strain rates. The results were used for calibration of a material model capturing the viscoplastic behavior at higher temperatures. Finally, to illustrate the key process steps, results from a complete process analysis are reported comprising the initial stress build-up during cooling and the initial out-of-roundness and out-of-roundness of the liners after various machining operations.
Materials and Manufacturing Technology, Chalmers Univ. of Technology,
Division of Material and Computational Mechanics, Dept. of Applied Mechanics, Chalmers Univ. of Technology,
Stock #: MPC104382