ARCHI VES

o f
F OUNDRY ENGI NEERI NG



Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences
ISSN (1897-3310)
Volume 10
Issue 4/2010

69 76

13/4

A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 1 0 , I s s u e 4 / 2 0 1 0 , 6 9 - 7 6 69

Towards optimization of stress simulation in
real casting-mould systems

Z. Ignaszak
Pozna University of Technology,
3 Piotrowo Street, 60-965 Pozna, Poland.
Corresponding author. E-mail address: zenon.ignaszak@put.poznan.pl

Received 20.07.2010; accepted in revised form 28.07.2010


Abstract

The simulation codes using from many years by foundry industry such e.g. Magmasoft, NovaFlow&Solid and ProCast, contain also the
thermo-mechanical modules permitting the estimation of mechanical stresses/deformations in casting during its cooling. It is also known
that these modules are rarely used because of the very limited thermo-mechanical database especially for ceramic materials such as
foundry sand mould. These technologies castings pouring in non-permanent sand moulds, particularly iron alloys are most often applied
in foundry. In our study the method of evaluating the algorithms quality applied in thermo-mechanical phenomena models based on
parameters sensitivity testing from the proper database of the simulation system was used [1]. The comparative analyses of both
experimental and virtual results were realized (by stress estimation). Methodology of experimental research was resemble to that described
in provided that the applied gray cast iron casting of stress bars (grid) were casted in sand mould bonded by organic resins. Also the
usefulness of author's method called Hot Distortion Plus

consisting in acquisition of temperature/distortion curves of heated sample of

sand mould material and correlation with curves of their dilatation and also the inverse solution method are signalized as new proposition
to estimate the chosen mechanical moulds parameters.

Keywords: Information technology in the foundry industry, Stress modeling, Cast iron castings, Casting-sand mould systems,
Foundry simulation codes, Hot distortion plus method



1. Introduction

The thermal theory of foundry processes describes not only
the course of heat transfer phenomena in the castmould system.
The majority of hypotheses of other particular complex
phenomena and their combination (coupling) are also related to
thermal theory [2].
The successful creation and application of socalled coupled
models are more and more frequent. These models connecting
energy production and transfer, mass transfer, mechanical
phenomena state and their effects are present in the theory and in
the practice of foundry. These simulation systems, called also
simulation codes are actually widely used in world foundries as
the optimization tool for technological studies by Virtual
Prototyping method, but they demand permanent improvement
studies.
The simplest models often need the parameter identification to be
exactly connected with final experiment. When the essential
modeling equations are known, we are looking for the missing
coefficients in the differential equations. In fact, reconstruction of
thermo-mechanical conditions put on mould (heated by the liquid
alloy) and study the assumptions to construct suitable apparatus
must be based on series of simplifications, together with
simultaneous test for standardization and repeatability of the tests
[3]. It is also known that these thermo-mechanical modules in
foundry simulation codes are rarely used because of the very
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 1 0 , I s s u e 4 / 2 0 1 0 , 6 9 - 7 6 70
limited thermo-mechanical database especially for ceramic
materials such as moulding sand [46].
These classic technologies castings pouring in non-permanent
sand moulds, particularly iron alloys are most often applied in
foundry. In our study the method of evaluating the algorithms
quality applied in thermo-mechanical phenomena models based
on parameters sensitivity testing from the proper database of the
simulation system was used.


2. Problem of data bases - permanent
challenge for creators and users
of simulation systems

The current opinion of majority users that material data bases in
commercial simulation systems are guilty for inaccurate or
unsatisfactory prediction results is not quite right. Catalog-
encyclopedic bases mentioned above play the role in the system
testing data, preliminary data or referenced. This concerns not
only physical data attributed to physical law (describing specific
phenomenon equation but also data operated the linked coupling
empirical models (or criteria) [7].
The consideration mentioned above considers not only typical
thermo-physical mould materials parameters (thermal
conductivity, specific and latent heat, heat transfer coefficient) but
particularly the thermo-mechanical parameters (E Young
elastic modulus, Poisson ratio, Re Yield stress, thermal
expansion coefficient).
It should be realized that parameters values from data bases
received in time-temperature conditions not fitted to conditions of
future usage of these parameters. Especially this remark concerns
the simplified models which describe the real process. The reason
of missing any kinds of possibilities to define the margin of error
of quality prediction result basing on virtual modeling seems
necessary to analyze and identify.

Set-up example of mechanical parameters for selected
materials is shown in Table 1.

Table 1.
Comparison of two mechanical parameters (E, ) for chosen
materials (approximate from different sources)
Material Young's Modulus
(Modulus
of Elasticity)
E [GPa]
Thermal Expansion
Coefficient
[1/K]
Steel 210-220 about 1.110
-5

Cast iron 83-170 about 1.010
-5

Aluminum 69 2.510
-5

Concrete 20-50 110
-5

Wood 9-12 0.510
-5

Quartz (fused) 72 0.6-1.410
-6

Epoxy resins 2,1-5,5 6-21 10
-5

Mould sans 0,1-100 (???) 1-2.5 10
-5
(???)



3. Stress modules in chosen foundry
simulation codes

The most frequent applied simulation systems in foundry
technology like Magmasoft, NovaFlow&Solid (NF&S) and
ProCast are optionally equipped with Stress modules. It requires
the user knowledge already in pre-processing stage. At Fig. 1 such
example for NF&S system is presented.


























Fig. 1. Principal stages realized during stress-deformation
calculations with the use of NF&S system the sub-modules of
stress procedures are marked (based on [8]).

The Stress modules of mentioned simulation codes allows to
perform a thermo-mechanical calculation. The typical results
deformations (elastic/plastic), displacements, dynamic gap
formation between casting and mould, elastic springback (only for
ProCast), die-mould fatigue, hot tears factor [9].
In NF&S there is access to two models Stress: Elastic module and
Elasto-plastic model [8].
In Magmasoft system [10] the Stress module enables the solution
such problems as Residual stress and distortion, hot tear tendency
in sand and die casting (in metallic dies too). These modules are
not quite known by users. The specialists in foundries apply it
very seldom. There is no literature information about the
validation of models applied in mentioned systems and about
confirmation of stresses fields prediction.
The indication of potential cracking zones menaced by appearing
(in the highest stresses sites) is quite easy to approximate predict
for foundrymanspecialist even without simulation calculation
employment. It always takes place near the hot spots (material
agglomeration in the casting walls crossing). The predictions of
3D Import
Initial setings
Flow&Solid
NovaStress
Browser
Parameters of mesh
Alloy&Mould Materials
Set gating points
Set sensors

Stress calculation model
(elastic, elastoplastic)
Set list
of records

A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 1 0 , I s s u e 4 / 2 0 1 0 , 6 9 - 7 6 71
these zones using Stress modules of all above listed systems
confirm that fact. However the evaluation of casting crack or/and
deformation appeared, caused by stress with high probability is
impossible. There are need such test investigations as proposed in
this paper e.g. utilization of stress grid (standard in foundry) as
validation experiment. There will be comparison of the simulation
results with the use of Stress modules for all three simulation
systems [11].
There will be the simplest models application in each system
(Elastic model). The basic material parameter (Young modulus,
Thermal Expansion Coefficient) will be applied in order to
estimate models sensitivity comparing with experiment results
(standard stress grid made of grey cast iron).


4 Experiments and numerical studies

4.1. Stress grid experimental research

The test casting as special grid stress (according to proper foundry
standard) was chosen to stress level validation. This casting is
made of cast iron. The methodology of this test takes into
consideration the combined influence estimation on stress level
not only specific construction of grid casting but also the type of
mould material (mould sand). In Fig. 2 the photo set illustrating
the moulding run is presented. The castings were left in mould
after pouring for 12 hours. The castings were knocked out and left
to cool to ambient temperature. Following after cleaning the
middle rod was cut using saw up to spontaneous crack and it was
measured the surface of fracture S
f
(Fig. 3).























Fig. 2. Stress grid used to validate the level of stress in
simulations codes. A grid draft, B core boxes (bottom/upper) C
cores made of one tested mould material (reclaimed furan quartz
sand),
D stages of mould preparation (two materials)























Fig. 3. Stages of stress grid testing: A pouring of the moulds, B
individual stress grid casting, C cutting of middle bar, D
grid after cutting (crack below saw cut), E fracture surface
(S
f
)
From remained bar part it was made tensile bar specimen and
determined tensile strength R
m
. Knowing the surface of middle
bar value ( 30mm) S
30
it can be calculated the tensile stress
value in analyzed cross section:
bar
= R
m
(S
f
/ S
30
). The
bar
value
was related to stress level calculating using simulation systems.

4.2. Stress grid numerical study

In order to perform the simulation tests the NF&S simulation
system were used. In all simulation trials the materials were gray
cast iron and furan sand. In each system it was used the most
simple thermo-mechanical module i.e. elastic one. The thermo-
physical and thermo-mechanical mould materials parameters were
shown in Table 2.

Table 2.
Main characteristics of mould material (sand and steel)
Material parameter Mould sand
Die
(steel)
Density
aver
[kg/m
3
] 1600 7700
Specific Heat c
aver
[J/kgK] 938 450-750
Thermal Conductivity
aver
[W/mK] 1,06 20-31
Young's Modulus
aver
or E(T) [GPa] 0.1-100 140-210
Yield Stress
aver
or YS(T) [MPa] 1-10 1-1220
Therm. Expansion Coeff . * [1/K] 110
-6
or (T,) (T,)
Hardening Coefficient 0 0
Poissons Ratio 0.3 0.3
*
Therm. Expansion Coeff
*
. not exists as direct data in NF&S
A
.
B
.
C.
D.
A.
B.
C.
D
.
FRACTURE
E.
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 1 0 , I s s u e 4 / 2 0 1 0 , 6 9 - 7 6 72
The data for grey cast iron used during all simulations are (from
NF&S database): (T)=69507500, c(T)=550-800, (T)=40-50,
E(T)=0.5100, YS(T)=1132, (T)=0.250.5.
The simulation results (chosen tests) were show in Fig. 4 to7.
The stress values obtained by simulation were compared with
experimental results from stress grid made of grey cast iron. The
mean tensile stress from experiment (only with sand mould) is
equal approximately +80 to +90 MPa (30 mm rod) and the
compressive stress 40 to 45 (estimated, 15 mm rods).
The extreme materials values of thermo-physical and thermo-
mechanical parameters (cited partially in the Table 2) from NFS
database et from our experience applied allow to conclude that the
calculated results (stress/deformation) obtained with use of steel
die data were nearest to real stress values from experience cited
above (stress grid casted from grey cast iron in to sand mould).
But its evident that the casted grid permits to determine the
tensile stress in the central 30 rod due to both phenomena:
contraction of metal and expansion of mould material.
The first attempts of NFS stress model validation show that the
separate validation of casting and mould thermo-mechanical
parameters for Stress modules is the true challenge.





























Fig. 4. Stress grid casted in sand mould: geometry, meshing,
casting temperature field (A) and calculated stress (B) and
deformation (C), using Stress module (elasto-plastic) of NF&S
system (after 13 hours of cooling, T
final max
<100 C)




















Fig. 5. Calculated stress (A) and deformation (B) using Stress
module (elasto-plastic) of NF&S system (after 22 min of cooling,
T
final max
<100 C) virtually casted in steel die


























Fig. 6. Fictitious (simplified) stress grid casted in sand mould:
geometry, casting temperature field (A) and calculated stress (B)
and deformation (C), using Stress module (elasto-plastic) of
NF&S system (after 2.5 hours of cooling, T
final max
<100 C)



-13/-21.5 MPa
+4/17.5 MPa
B.
Exagg .ratio- 25%
1.5 mm
1.2 mm
C.
<100 C
A.
-41/+126 MPa
+32/-25 MPa
A.
1.7 mm
1.3 mm
Exagg. ratio- 25%
B.
-4/9 MPa
B.
0.7 mm
0.1 mm
C.
<100 C
A.
Exagg. ratio- 25%
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 1 0 , I s s u e 4 / 2 0 1 0 , 6 9 - 7 6 73
PYROMETER
THERMAL
CAMERA
DMA HD
APPARATUS
SPECIMEN
DISTORTION
SENSOR
GAS BURNER



















Fig. 7. Fictitious (simplified) stress grid casted in in steel die:
calculated stress (A) and deformation (B) using Stress module
(elasto-plastic) of NF&S system
(after 4 min of cooling, T
final max
<100 C)

The next figure (Fig. 8.) presents the results corresponding to two
cases of virtually tested moulds.




















Fig. 8. Calculated stresses on the central section of the moulds
(fictitious stress grid ) using Stress module (elasto-plastic) of
NF&S system. A sand mould, B steel die.

The first results with stress/deformation predictions from
Magmsoft and ProCast systems arent also satisfactory comparing
with experiment [11].
In this situation, to complete our investigations, the new series of
studies were realized, without applying of molten metal as heat
sources to test the mould material (i.e. quartz sand bonded by
furan resin).

4.3. Hot Distortion Plus

Test
experimental research

The hot distortion apparatus (DMA [12,13], modified according to
Z. Ignaszak idea (with supplementary devices, named: Hot
Distortion Plus

[14]) was applied. Necessary modifications of the

DMA apparatus were introduced: i.e. additional gas heating, the
Raytek pyrometer and the V50 thermovision camera provided
with own recording systems enabling analyzing variable
temperature field of the specimen. The modified measuring stand
is shown in Fig. 9. Gas heating was used. The specimen
temperature was recorded by pyrometer at the side opposite to the
heated surface. Temperatures of the heated and side surfaces were
recorded by means of the thermovision camera. The sample
deformation was measured by special sensor located on the free
specimen tip. The photos made during the tests are shown also in
Fig. 9. The tests were carried out for the new quartz sand bonded
by furan resin (approx. 1%) chemically hardened by PTS
catalyst agent.


Fig. 9. Scheme of the HD Plus system. Scheme of modified
measuring stand containing DMA apparatus.

4.4. Hot Distortion Plus

Test
numerical study

All thermo-mechanical problems considered in this work are
governed by chosen partial differential equations (PDEs) with
appropriate boundary and initial conditions. Numerical results for
3D systems are obtained using standard computational code
COMSOL Multiphysics [15,16]. COMSOL Multiphysics is a
powerful interactive environment for modelling and solving the
majority kinds of scientific and engineering problems based on
coupled partial differential equations (PDEs) using the finite
element method (FEM) [17].
The authors show how to estimate the mechanical parameters
Young (elastic) modulus and thermal expansion coefficient
for a rectangular prism sample to achieve satisfactory agreement
between experimental and computational results. There is a
+4 MPa
-1.2 MPa
A.
B.
-10 MPa
-23 MPa
-70/+123 MPa
A.
0.8 mm
0.1 mm
B.
Exagg. ratio- 25%
PYROMETER
THERMAL
CAMERA
DMA HD
APPARATUS
SPECIMEN
DISTORTION
SENSOR
GAS BURNER
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 1 0 , I s s u e 4 / 2 0 1 0 , 6 9 - 7 6 74
Numerical experiment HD Plus

Temperature upper

number of physical properties that are temperature independent.
In this paper Young modulus E=E(T) and thermal expansion
coefficient =(T) are considered as temperature dependent as
well. The principle of homogenization used in this model of
porous and multiphase material permits to simplify the volumic
characterization of its properties. These temperature dependent
relations have great influence on material behaviour and
deformation during heating.
The problems are solved with COMSOL code using direct
SPOOLES or UMFPACK linear system solver. Relative and
absolute tolerance used in calculations are 0.01 and 0.001,
respectively. Quadratic Lagrange shape function with tetrahedral
element is used for solid stress-strain mode and linear Lagrange
shape function with tetrahedral element is used for heat transfer
mode.
The of theoretical bases of model and numerical methodology
were presented in [17,18].
The preliminary test were obtained using constant
(temperature independent) values of thermal furan sand
coefficients (see Fig.10). The results show very good agreement
concerning temperature variations. Simultaneously the
comparison of experimental and numerical results for distortion of
specimen was non-satisfactory when the constant values of E and
were assumed (Fig. 11).
Due to this non-conformity the new approach concerning E and
was introduced. The intuitive temperature variations of E=E(T)
and =(T) resulting from our experience on thermo-mechanical
behaviours in considered material in the contact with high
temperature was analyzed. Many numerical tests were done using
the wide range of parameters values resulting from E=E(T) and
=(T) formulas. A good agreement between real (measured by
HD Plus test) and simulated distortion curves was assumed as the
goal criterion.
The final formulas estimation of temperature dependent E=E(T)
and =(T) allow to obtain expected agreement for measured and
simulated distortions (see Fig. 11).


























































Fig. 10. Comparison of experimental and simulated curves of
heated specimen, A experimental results, B calculated results
on the bottom specimen surface, C calculated results on the
higher specimen surface (B,C calculated by COMSOL
Multiphysics code) [17]


5. Summary

The investigations results obtained by experimental way and
simulation method can be summarized as follows:
1. The different ways to investigate the stress/deformation
phenomena and to validate the stress modules in the most
frequently used foundry simulation codes was described.
2. Applying the mentioned modules which simulate the stress
phenomena based on the relatively simplest models the
unexplained differences in calculated stress values were
obtained.

A.
C.
Time, s
T
e
m
p
e
r
a
t
u
r
a
,

C

Numerical experiment HD Plus

Temperature bottom

B.
Time, s
T
e
m
p
e
r
a
t
u
r
a
,

C

SPECIMEN HD, NEW SAND+ET ORGANIC RESIN,
GAS HEATING (MEDIUM INTENSITY)
0
100
200
300
400
500
600
700
800
0 10 20 30 40 50 60 70 80 90 100 110 120
TIME in sec
T
E
M
P
E
R
A
T
U
R
E

i
n

C
EXP-UPPER EXP-BOTTOM
Real experiment HD Plus

Temperature

bottom surface
upper surface
Time, s
T
e
m
p
e
r
a
t
u
r
a
,

C

A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 1 0 , I s s u e 4 / 2 0 1 0 , 6 9 - 7 6 75




















































3. The influence of fine/coarse mesh and also time step are
observed for all used simulation codes [17].
4. The complex stress (stress grid construction, presence of
gating system) disturbing the run of stress calculations have
the heterogeneous character for each codes and influence
the virtual stress/deformation maps.
5. The creators of simulation codes (including Stress Module)
dont make algorithm structure available to users. Also the
user hasnt got to estimate the quality of models regarding
the simplification state which were applied in stress-
displacement model comparing with constitutive law.
6. The obtained results of stress predictions there are not
satisfactory yet to apply to predict the stress maps in
industrial (often complicated) casting. The decision
concerning accepted stress limit by virtual way is not sure.
Another modules accessible in described codes (e.g. visco-
elasto-plastic) are planned to test in the next stages of study.
7. Using HD Plus

test the interesting validation stage (after

thermal validation described in [18]) of coupled model
describing the thermo-mechanical phenomena in porous
thermolabile materials represented by quartz sand bonded
by chemically hardened resin (furan resin with PTS acid), ,
was also presented.
8. It turned out that application of the simplest type of
mechanical model (e.g. elastic, in this case) and temperature
dependent parameters E(T) and (T) allow to obtain
also expected agreement of measured and simulated
distortions for sand sample exposed to intensive heating.


Acknowledgements

The acknowledgements are addressed for Novacast group and
for Metals Minerals team to make the NFS code available (from
more than 10 years in our Laboratory) to test/validate its modules,
and also to Mrs Gorny and Piech for the collaboration. I present
too my thanks to Mrs Dr P.Popielarski and Dr T.Strek from
Poznan University of Technology for their assistance.


References

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0.00E+00
5.00E-04
1.00E-03
1.50E-03
2.00E-03
2.50E-03
0 20 40 60 80 100 120
Time [s]
T
o
t
a
l

D
i
s
p
l
a
c
e
m
e
n
t

[
m
]
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0
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0 10 20 30 40 50 60 70 80 90 100 110
czas [s]
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Temperature upper

D
i
s
t
o
r
t
i
o
n
i
m
,
m
m

E=1e10 Pa, =2,2e-5 1/K
A.
0.0E+00
2.0E+09
4.0E+09
6.0E+09
8.0E+09
1.0E+10
1.2E+10
0 200 400 600 800 1000 1200 1400
Temerature [K]
E

[
P
a
]
0.0E+00
4.0E-06
8.0E-06
1.2E-05
1.6E-05
2.0E-05
2.4E-05
A
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p
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a

[
1
/
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]
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a
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i
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o
e
f
f
.

1
/
K

Temperature, K
E
l
a
s
t
i
c

m
o
d
u
l
u
s
,

M
P
a

Fig. 11. Comparison of measured and simulated distortion curves
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for quartz sand bonded by 1% of furan resin and comparison
(B,C) [17].

A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 1 0 , I s s u e 4 / 2 0 1 0 , 6 9 - 7 6 76
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