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Predicting Residual Stresses Due to Solidification in Cast Plastic Plates VladoTropsaPhD

May 30, 2018

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    -

    z=-L

    z=0

    z=+L

    T=T(z)

    y

    z

    x 2L

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    T=T(z)

    z=0

    z

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    0

    T=T(z)

    undeformed state

    T (z)rem

    T (z)asym

    T_

    0

    0 = 0

    0 = 0 =

    =

    =

    +

    +

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    0

    E(t-0)

    t

    E(t- )

    E(t)

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    t=t

    t=0

    T(z,t)z

    T(z)

    t0

    z=L

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    _

    _

    +

    _

    _

    z

    E(t)

    t0 t

    t'0

    T(z) res( z,t )1 res(z,t )2

    t2t1

    E(t)

    0

    0E(t-t )=E(t')

    +

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    0 =( )

    t

    T t1

    E(t, )=E( )Tref

    E(t,T)E(t,T) T >Tref

    Tref

    ( )=1Tref

    log T( )

    log (t)

    E(t,T) ; T >Tref

    t1 t2

    2

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    -

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    t

    T(z,t)

    z=L

    T=T

    t

    z=L

    T=Tg

    T(z,t)

    z

    g

    z

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    -

    -

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    -

    -

    -

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    -

    -

    -

    -

    - - -

    -

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    Mathcad implementation procedure:F_left( )x cot( )..2 x L F_right( )x

    x

    .2 H

    H

    .2 x

    roots_( )N guess.1

    2

    .2 L

    for

    guess guess

    .2 L

    n

    root ,F_left guess F_right guess guess

    guess n

    n ..0 N 1

    . m1

    =roots_( )3

    277.565

    557.186

    840.345

    1

    m

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    0

    50

    100

    150

    200

    temperature(oC)

    cooling time (s)

    0 60 120 180 240

    z=5.00 mm (top surface)

    z=3.75 mm

    z=2.50 mm

    z=1.25 mm

    z=0.00 mm (middle surface)

    -5.0

    -2.5

    0.0

    2.5

    5.0

    thicknesscoordinatez(mm)

    temperature ( oC)

    0 50 100 150 200

    201

    510

    2030

    6090

    4050

    120

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    0

    50

    100

    150

    200

    temperature(oC)

    cooling time (s)

    0 120 240 360 480 600

    z=10.00 mm (top surface)

    z=7.50 mm

    z=5.00 mm

    z=2.50 mm

    z=0.00 mm (bottom surface)

    0.0

    2.5

    5.0

    7.5

    10.0

    thicknesscoordinatez(mm)

    temperature ( oC)

    0 50 100 150 200

    20

    15

    3060

    120180

    240300

    360

    1020

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    Tg

    0

    50

    100

    150

    200

    temperature(oC)

    cooling time (s)

    0 60 120 180 240

    z=5.00 mm (top surface)

    z=3.75 mm

    z=2.50 mm

    z=1.25 mm

    z=0.00 mm (middle surface)

    42.5 s

    113.9 s

    -5.0

    -2.5

    0.0

    2.5

    5.0

    thickne

    sscoordinatez(mm)

    temperature ( oC)

    -50 0 50 100 150 200

    60

    0

    113.9

    10014080

    42.5

    20

    ( ) T zresTg

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    0

    50

    100

    150

    200

    temperature(oC)

    cooling time (s)

    0 60 120 180 240 300

    full temperature solution (n=100)

    aproximate solution (n=1)

    middle surface

    top/bottom surface

    Tg 2

    Tg1

    Tg 3

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    - -

    - - -

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    sol

    t=const

    'frozen-in'gradientfield

    (t+dt)=const

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    -

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    -

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    -

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    symmetryplane

    T=Tg

    T=Tg

    gradT

    symmetry

    plane

    gradT

    gradT

    orthogonal lines

    -

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    A

    B B

    A

    B

    A A

    a) Solidification fronts b) Orthogonal lines

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    a) Solidification fronts b) Orthogonal lines

    weld line

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    -

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    -

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    P

    f

    S

    y

    z

    x

    r

    N

    CV

    f

    -

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    P Nf

    nfdPN

    (a) orthogonal mesh

    P Nf

    nfdPN

    (b) non-orthogonal mesh

    nf

    o

    k

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    -

    -

    -

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    F

    x

    y

    y

    u

    x

    uyy

    >>

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