Geometrical Optimization of the Cast Iron Bullion Moulds Based on Fracture Mechanics
الموضوعات :A Niknejad 1 , M Karami Khorramabadi 2 , M.J Sheikhpoor 3 , S.A Samieh Zargar 4
1 - Faculty of Engineering, Payame Noor University (PNU), Yazd Branch
2 - Department of Mechanical Engineering, Islamic Azad University, Khorramabad Branch
3 - Faculty of Engineering, Payame Noor University (PNU), Yazd Branch
4 - Faculty of Engineering, Payame Noor University (PNU), Yazd Branch
الکلمات المفتاحية: Optimization, Fatigue, Creep, Crack Propagation, Cast iron,
ملخص المقالة :
In this paper, the causes of the crack initiation in cast iron bullion moulds in Meybod Steel Corporation are investigated and then some new geometrical models are presented to replace the current moulds. Finally, among the new presented models and according to the life assessment, the best model is selected and suggested as the replaced one. For this purpose, the three recommended moulds were modeled and analyzed by ANSYS software. First, a thermal analysis and then a thermo-mechanical coupled field analysis were performed on each three model. The results of the analysis are used to determine the critical zone. The critical zone is selected on the symmetric axis of the inner surface of the mould. By comparing the principle stress contours and temperature distribution contours of three models, one of the suggested models was selected as optimized geometrical model. Then, the crack modeling and the life assessment on the optimized model were implemented and the total life of the model was calculated. Comparison of the life of the optimized and the initial models shows an increase in the life of the suggested model. The results are verified with the experiments.
[1] Niknejad A., Samieh Zargar S.A., Sheikhpour M.J., 2009, Investigation of the life assessment and the crack propagation in the molds of cast iron bar, in: Proceeding of the 17th International Conference on Mechanical Engineering, Tehran, Iran (in Persian).
[2] Ishihara S., Nan Z.Y., McEvily A.J., Goshima T., Sunada S., 2008, On the initiation and growth behavior of corrosion pits during corrosion fatigue process of industrial pure aluminum, International Journal of Fatigue 30: 1659-1668.
[3] Xu Y., Yuan H., 2008, Computational analysis of mixed-mode fatigue crack growth in quasi-brittle materials using extended finite element methods, Engineering Fracture Mechanics 30: 1780-1786.
[4] Ranganathan N., Chalon F., Meo S., 2008, Some aspects of the energy based approach to fatigue crack propagation, International Journal of Fatigue 30: 1921-1929.
[5] Wang Y., Cui W., Wu X., Wang F., Huang X., 2008, The extended McEvily model for fatigue crack growth analysis of metal structures, International Journal of Fatigue 30: 1851-1860.
[6] Borrego L.P., Ferreira J.M., Costa J.M., 2008, Partial crack closure under block loading, International Journal of Fatigue 30: 1787-1796.
[7] Jones R., Molent L., Pitt S., 2008, Similitude and the Paris crack growth law, International Journal of Fatigue 30: 1873-1880.
[8] Kagawa H., Morita A., Matsuda T., Kubo S., 2008, Fatigue crack propagation behavior in four-points bending specimens with multiple parallel edge notches at regular intervals, Engineering Fracture Mechanics 75: 4594-4609.
[9] Herrera A.G., Zapatero J., 2008, Tri-dimensional numerical modeling of plasticity induced fatigue crack closure, Engineering Fracture Mechanics 75: 4513-4528.
[10] Cojocaru D., Karlsson A.M., 2008, An object-oriented approach for modeling and simulation of crack growth in cyclically loaded structures, Advances in Engineering Software 39: 995-1009.
[11] Liljedahl C.D.M., Fitzpatrick M.E., Edwards L., 2008, Residual stresses in structures reinforced with adhesively bonded straps designed to retard fatigue crack growth, Composite Structures 86: 344-355.
[12] Uematsu Y., Tokaji K., Kawamura M., 2008, Fatigue behavior of Sic-particulate-reinforced aluminum alloy composites with different particle sizes at elevated temperatures, Composites Science and Technology 68: 2785-2791.
[13] Castillo E., Canteli A.F., Pinto H., Ruiz-Ripoll M.L., 2008, A statistical model for crack growth based on tension and compression Wohler fields, Engineering Fracture Mechanics 75: 4439-4449.
[14] Fan F., Kalnaus S., Jiang Y., 2008, Modeling of fatigue crack growth of stainless steel 304L, Mechanics of Materials 40: 961-973.
[15] Bogdanski S., Lewicki P., 2008, 3D model of liquid entrapment mechanism for rolling contact fatigue cracks in rails, Wear 265: 1356-1362.
[16] Giner E., Sukumar N., Denia F.D., Fuenmayor F.J., 2008, Extended finite element method for fretting fatigue crack propagation. International Journal of Solids and Structures 45: 5675-5687.
[17] Mirzaei M., Niknejad A., 2004, Investigation of the crack growth and life assessment of the copper slag pot, in: Proceeding of the 12th International Conference on Mechanical Engineering, Tehran, Iran (in Persian).
