Volume 1, Issue 1

    Modeling of Distortion during Casting and Machining of Aluminum Engine Blocks With Cast-in Gray Iron Liners

    (Received 1 October 2011; accepted 29 March 2012)

    Published Online: 2012

    CODEN: MPCOAD

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    Abstract

    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.


    Author Information:

    Ahlström, Johan
    Materials and Manufacturing Technology, Chalmers Univ. of Technology,

    Larsson, Ragnar
    Division of Material and Computational Mechanics, Dept. of Applied Mechanics, Chalmers Univ. of Technology,


    Stock #: MPC104382

    ISSN: 2165-3992

    DOI: 10.1520/MPC104382

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    Author
    Title Modeling of Distortion during Casting and Machining of Aluminum Engine Blocks With Cast-in Gray Iron Liners
    Symposium , 0000-00-00
    Committee E28