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由于铸造工艺的缘故,导致气缸盖的材料高周疲劳特性分布不均匀。为了模拟制造工艺对铸件机械性能的影响,Ford汽车公司开发了虚拟铝铸造工具。虚拟铝铸造的特点之一是能预测高周疲劳强度分布。由于残余应力对气缸盖的高周疲劳也起着重要作用,因此对残余应力也进行了模拟,并将其用于气缸盖的高周疲劳分析。采用ABAQUS~(TM)软件对气缸盖总成、热应力和工作应力进行模拟。将工作应力与残余应力结合在一起,进行高周疲劳计算。采用FEMFAT~(TM)疲劳测试有限元分析软件进行高周疲劳分析。基于虚拟铝铸造模拟获得的局部材料特性,建立了用户定义的赫氏图。结果证明,利用在FEMFAT~(TM)软件中得到的局部特性分布,可显著提高气缸盖高周疲劳模拟结果的精确度。
Due to the casting process, the high-cycle fatigue characteristics of the cylinder head material are unevenly distributed. In order to simulate the manufacturing process on the mechanical properties of the casting, Ford Motor Corporation has developed a virtual aluminum casting tool. One of the features of virtual aluminum casting is the ability to predict the high-cycle fatigue strength distribution. Since the residual stress also plays an important role in the high-cycle fatigue of the cylinder head, the residual stress is also simulated and used for the high-cycle fatigue analysis of the cylinder head. The cylinder head assembly, thermal stress and working stress were simulated using ABAQUS ™ software. The work of stress and residual stress together, high cycle fatigue calculations. High-cycle fatigue analysis using FEMFAT ~ (TM) fatigue test finite element analysis software. Based on the local material properties obtained from the virtual aluminum casting simulation, a user-defined Hertzian graph was established. The results show that using the local characteristic distribution obtained in FEMFAT ™ software can significantly improve the accuracy of high-cycle fatigue simulation of cylinder head.