Residual Stress Prediction in the Casting Process of Automotive Powertrain Components

Residual stress development during the manufacturing process of powertrain components, such as engine blocks, is a primary source of premature failure. Residual 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 stresses 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 stress evolution in engine blocks during the casting procedure. To determine proper modelling and process parameters, the simulation was initially conducted on a simplified standard geometry. Then, the casting process of an I6 bore-chilled sand-cast engine block was simulated in ANSYSTM. The results revealed that there was a positive correlation between the predicted residual stresses and neutron diffraction data, specifically in the engine block’s axial orientation.