A simulation-based design paradigm for complex cast components

This paper describes and exercises a new design paradigm for cast components. The methodology integrates foundry process simulation, non-destructive evaluation (nde), stress analysis and damage tolerance simulations into the design process. The foundry process simulation is used to predict an array of porosity related anomalies. The probability of detection of these anomalies is investigated with a radiographic inspection simulation tool (xrsim). The likelihood that the predicted array of anomalies will lead to a failure is determined by a fatigue crack growth simulation based on the extended finite element method, xfem and therefore does not require meshing nor remeshing as the cracks grow. In this approach, the casting modelling provides initial anomaly information, the stress analysis provides a value for the critical size of an anomaly and the nde assessment provides a detectability measure. The combination of these tools allows for accept/reject criteria to be determined at the e...

• Type: Journal
• Year: 2007
• Where: EWC
• Authors: Stéphane P. A. Bordas, James G. Conley, Brian Moran, Joe Gray, Ed Nichols
• Keywords: EWC 2007, Foundry Process Simulation, Simulations, finite Element Method