Residual Stress Prediction in the Casting Process of Automotive Powertrain Components

Residual stressResidual stress development during the manufacturing process of powertrain components, such as engine blocksEngine block, is a primary source of premature failure. Residual stressResidual stress may induce in-service dimensional instability and crack formations, which poses challenges for developing high-efficiency engines. Hence, adopting a reliable approach for accurate prediction and characterization of residual stressesResidual stress plays a vital role in efficient stress management. Advanced numerical techniques using versatile finite element methods are viable tools for stress analyses. The current study develops a numerical model of the residual stressResidual stress evolution in engine blocksEngine block during the casting procedure. To determine proper modelling and process parameters, the simulationModelling and simulation was initially conducted on a simplified standard geometry. Then, the casting process of an I6 bore-chilled sand-cast engine blockEngine block was simulated in ANSYSTM. The results revealed that there was a positive correlation between the predicted residual stressesResidual stress and neutron diffraction data, specifically in the engine block’s axial orientation.