Journal Published Online: 01 September 2012
Volume 1, Issue 1

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



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, SE
Larsson, Ragnar
Division of Material and Computational Mechanics, Dept. of Applied Mechanics, Chalmers Univ. of Technology, SE
Pages: 19
Price: $25.00
Reprints and Permissions
Reprints and copyright permissions can be requested through the
Copyright Clearance Center
Stock #: MPC104382
ISSN: 2165-3992
DOI: 10.1520/MPC104382