Numerical simulation of central shrinkage crack formation in a 234-t steel ingot

Central shrinkage crack is a common defect encountered in steel ingot casting. It is necessary to limit the degree of crack in case of further propagation in forging. A 234-t steel ingot was dissected to check the internal quality, and a central shrinkage crack band of 1,400 mm in height and 120 mm...

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Bibliographic Details
Published in:China foundry 2017-09, Vol.14 (5), p.365-372
Main Authors: Yang, Jing-an, Wang, Yue-qiao, Shen, Hou-fa, Liu, Bai-cheng
Format: Article
Language:English
Subjects:
Analysis
Casting (Metal)
crack potential
Engineering
Finite element method
finite-element
Machines
Manufacturing
Materials Engineering
Mechanical properties
Metal castings
Metallic Materials
Numerical analysis
Porosity
Processes
shrinkage crack
Steel
steel ingot
thermo-mechanical simulation
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Summary:Central shrinkage crack is a common defect encountered in steel ingot casting. It is necessary to limit the degree of crack in case of further propagation in forging. A 234-t steel ingot was dissected to check the internal quality, and a central shrinkage crack band of 1,400 mm in height and 120 mm in width, was found at a distance of 450 mm under the riser bottom line. Then, thermo-mechanical simulation using an elasto-viscoplastic finite-element model was conducted to analyze the stress-strain evolution during ingot solidification. A new criterion considering mush mechanical property in the brittle temperature range as well as shrinkage porosity was used to identify the shrinkage crack potential, where the degree of shrinkage porosity is regarded as a probability factor using a modified sigmoid function. Different casting processes, such as pouring speed, mould preheating and riser insulation, were optimized with the simulation model. The results show that fast pouring, proper mould preheating and good riser insulation can alleviate shrinkage crack potential in the ingot center.
ISSN:1672-6421
2365-9459
1672-6421
DOI:10.1007/s41230-017-7160-5