Ragnar Larsson, Professor Johan Ahlström, Ph D

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Presentation transcript:

Ragnar Larsson, Professor Johan Ahlström, Ph D MCR - Chalmers University of Technology Dept. of Applied Mechanics/Materials and Manufacturing Technology Gothenburg, Sweden Håkan Sterner Volvo Cars Engine Process Development CDS-id = hsterner MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Measured out-of-roundness (OOR) Picture shows OOR before machining at 5 positions Circles are reference lines The outer curve = the upper part of cylinder - oval! The inner curve = the lower part of cylinder - square! MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Improved Quality and reduced Costs Problem: High residual stresses arise during casting of engine blocks with liners of cast iron due to differences in thermal expansion. Unwanted out-of-roundness (OOR) during machining of cylinders. Targets: A working model for prediction of form distorsions due to residual stress Improved Quality and reduced Costs Improved future cylinder block design MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Simulate the casting process with preliminary material models Approach/Methods: Simulate the casting process with preliminary material models Material analyses and implementation into better material models Improved calculations of distortions and residual stresses after casting Measure residual stresses Measure machined parts Simulate the machining process Compare results Compare results MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

The full FE-model, block and liners The block is high-pressure die-cast from aluminium (blue) Liners of cast iron (orange) ca 260 000 elements MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

High-pressure die-casting of blocks Cast iron liners are fixed into the die Aluminium melt (AlSi9Cu3) is pressed into the die; filling time 130 ms Ejected after 25 s; temperature ca 350°C Air cooling at pallets, according to fig. (ca 1 h cooling to 50°C) Trimming and grit blasting MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Preparations before mechanical computation Thermal computation - cooling by convection Assumptions of the relative values of the film coefficients h Adjustment of absolute levels to match the measured cooling rate DOF: ca 540 000 CPU-time: < 1 h Compensation for thermal contraction Red = high convection MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Mechanical computation Done in steps: Thermal contraction and generation of residual stresses, reading the temperature field from the thermal simulation (down to ca 50 °C) Residual cooling in one step down to 20°C (no relaxation at low temp.) Preliminary machining simulation: top/bot surfaces, oil tube, crank case ventilation Preliminary machining simulation: liners and water slots between cyl. Ca 2.6 106 DOF Ca 30 CPU hours MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Material volumes removed in steps 3-4 ca 30 000 elements ca 50 000 elements MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Computed vs measured OOR after cooling near the top plane von Mises stress Deformations magnified 20x OOR, cyl. 2 – 4 x-direction y-direction Computed rnom – 0.2 mm rnom + 0.2 mm Measured rnom + 0.15 mm MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

von Mises stresses in the block After step 2 After step 4 After step 3 MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Improve the material model for the aluminium. Master’s thesis running: Future work Improve the material model for the aluminium. Master’s thesis running: tensile testing of block material at different temperatures and strain rates. material models are evaluated and calibrated (efficient models) Improve the material model for the cast iron. Data available through cooperation with Volvo AB. Implement direction-dependent friction between liner and block Residual stress measurements at Volvo Powertrain Improved modelling of machining Compare results between computations and measurements MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Thank you for your attention! MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers

Preliminary material model MERA-programmet/programkonferensen 2007-02-06, projekt: 2006-00126, Ragnar Larsson/Tillämpad mekanik, Chalmers