Numerical Simulation of Thermal Stress and Deformation in a Casting Using Finite Difference Method

Abstract

A software code for simulating thermal stress in castings was developed using finite difference method (FDM). The one way coupled map model was adopted to treat the relationship between the solidification and the thermal stress in castings. A method of killing the mold element whose temperature begins to decrease was employed to deal with the mold/casting interaction. The thermal stress and deformation in a stress frame casting were experimentally studied and analyzed by this software code. The results simulated and the residual stress measured are in good agreement. This indicates that the software code is a useful tool for predicting thermal stress and deformation in castings. Therefore, it provides a scientific way to improve the casting dimensional accuracy and reduce the defects caused by thermal stress.