DOI
10.17077/etd.1zam4k3k
Document Type
Thesis
Date of Degree
Fall 2013
Degree Name
MS (Master of Science)
Degree In
Mechanical Engineering
First Advisor
Beckermann, Christoph
First Committee Member
Zhupanska, Olesya I
Second Committee Member
Udaykumar, H S
Abstract
An elasto-visco-plastic deformation model predicts stresses and distortions in a low-carbon steel casting. Features of the model include rate and hardening effects, temperature-dependent properties, and pressure-dependent deformation in the mushy zone. A volume-averaging technique considers the multiple phases during solidification and is used to formulate the conservation equations, which (due to a weak link between temperatures and deformations) are decoupled and solved sequentially using commercial software. Temperature fields are calculated first using MAGMAsoft (MAGMAsoft, MAGMA GmbH, Kackerstrasse 11, 52072 Aachen, Germany) and then exported to a finite element software package, ABAQUS (Abaqus/Standard, Abaqus, Inc., Providence, RI, 2006), which predicts stresses and distortions. In order to simulate the conditions encountered in an industrial casting process, predicted temperatures and distortions are matched with experimental data from in situ casting trials. Preliminary simulations do not agree with the experimental distortions, which suggest that stress-strain data from mechanical tests (from which the mechanical properties were estimated) does not accurately characterize the material behavior of a casting during solidification and cooling. The adjustments needed to match measured and predicted distortions provide valuable insight to the effect a solidified microstructure has on its mechanical properties.
Keywords
casting, distortion, in situ, steel, viscoplastic
Pages
xvi, 132 pages
Bibliography
Includes bibliographical references (pages 128-132).
Copyright
Copyright 2013 Daniel Joseph Galles
Recommended Citation
Galles, Daniel Joseph. "Measurement and prediction of distortions during casting of a steel bar." MS (Master of Science) thesis, University of Iowa, 2013.
https://doi.org/10.17077/etd.1zam4k3k