Casting Mold Thermal Stress Simulation for Crack Risk Prediction
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Solution Overview
Problem
Existing methods fail to accurately predict thermal stress in casting molds during the service process, leading to early cracking and reduced service life, especially for complex automotive parts, necessitating a rapid and precise simulation method.
Innovation Solution
A method involving the creation of a finite element physical model, coupled with temperature-stress correction factors, to simulate and calculate thermal stress distribution in casting molds, considering material and thermal influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional simulation methods are used for thermal stress prediction, then the prediction process is simple, but the prediction accuracy is low leading to early cracking
Solution Approach 1:
The simulation process is divided into three distinct stages: (1) pure temperature field calculation, (2) coupled temperature and flow field calculation, and (3) coupled temperature, flow, and stress field calculation. This segmentation allows each stage to build upon the previous one, improving accuracy while managing complexity through progressive refinement.
Solution Approach 2:
The method performs preliminary temperature field calculations (6-10 cycles) and coupled temperature-flow field calculations (3-5 cycles) before conducting the final stress field analysis. This preliminary action establishes accurate thermal and flow conditions that are essential for precise thermal stress prediction, preventing early cracking through advance identification of high-risk areas.
2Measurement precision
If detailed material parameters and boundary conditions are incorporated, then the simulation accuracy improves, but the calculation time increases
Solution Approach 1:
The calculation process is segmented into three stages with increasing complexity. Stage 1 (6-10 cycles) uses basic material parameters for temperature field. Stage 2 (3-5 cycles) adds flow field coupling with enhanced parameters. Stage 3 (1 cycle) performs stress field calculation with complete coupled parameters. This segmentation reduces total calculation time compared to performing a single comprehensive simulation, while achieving high accuracy through progressive refinement.
3Duration of action of stationary object
If the mold structure is optimized to reduce thermal stress, then the service life extends, but the design complexity increases
Solution Approach 1:
The simulation method is applied during the product development stage to predict thermal stress distribution and identify high-risk cracking areas before mold manufacturing. This preliminary action allows designers to optimize mold structure (such as cooling channel layout, wall thickness distribution, and reinforcement positions) to reduce thermal stress, thereby extending service life without requiring complex trial-and-error modifications after production begins.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Accurately identifies mold cracking risks, reduces production costs, and extends mold service life by optimizing design and process parameters.
Implementation Method 1
interface heat transfer parameters to contact interfaces in the model, a pressure process parameter to an inlet of a sprue, a cooling heat transfer parameter to a cooling channel surface
Implementation Method 2
performing solution calculations of 6-10 individual temperature field cycles based on the casting simulation finite element physical model and the casting simulation finite element calculation model
Implementation Method 3
obtain third-stage temperature field distribution and stress field distribution, where the third-stage temperature field distribution data includes all finite element grid node numbers and corresponding temperature values, and the stress field distribution data includes all finite element grid node numbers and corresponding stress values
Data Source
AI summary
The present invention discloses a method and apparatus for simulating thermal stress of a casting mold during a service process, and a storage medium. The method comprises: importing a pre-built three-dimensional geometric model of the casting mold, processing the geometric model, and then performing grid division to obtain a casting simulation finite element physical model; assigning material parameters, interface parameters, process parameters, and boundary conditions to the finite element physical model to obtain a casting simulation finite element calculation model; performing casting process simulation calculations to obtain casting simulation results such as mold temperature field and stress field, and exporting result data; interpolating a temperature-stress correction factor; multiplying all correction factor data under the same node numbers with mold stress data to obtain final thermal stress distribution data of the mold during the service process.