400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760 Web: www.sae.org SAE TECHNICAL PAPER SERIES 2006-01-0324 Development of Experimental Methods to Validate Residual Stress Models for Cast Aluminum Components J. V. Lasecki, Xuming Su and John E. Allison Ford Motor Company Reprinted From: Experiments in Automotive Engineering - Experimental Test (SP-2033) 2006 SAE World Congress Detroit, Michigan April 3-6, 2006 Downloaded from SAE International by University of Liverpool, Monday, August 13, 2018The Engineering Meetings Board has approved this paper for publication. It has successfully completed SAE's peer review process under th e supervision of the session organi zer. This process requires a minimum of three (3) reviews by industry experts. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. For permission and licensing requests contact: SAE Permissions 400 Commonwealth DriveWarrendale, PA 15096-0001-USAEmail: permissions@sae.orgTel: 724-772-4028 Fax: 724-776-3036 For multiple print copies contact: SAE Customer Service Tel: 877-606-7323 (inside USA and Canada)Tel: 724-776-4970 (outside USA)Fax: 724-776-0790Email: CustomerService@sae.org ISSN 0148-7191 Copyright © 2006 SAE International Positions and opinions advanced in this paper are those of the author(s ) and not necessarily those of SAE. The author is solely responsible for the content of th e paper. A process is available by which discussions will be printed with the pap er if it is publishe d in SAE Transactions. Persons wishing to submit papers to be considered for presentation or publicat ion by SAE should send the manuscript or a 300 word abstract to Secretary, Engineering Meetings Board, SAE. Printed in USADownloaded from SAE International by University of Liverpool, Monday, August 13, 2018ABSTRACT The prediction of residual stresses due to manufacturing is of high importance in product development. For the accurate prediction of residual stresses in metallic components, an understanding of the quenching process that occurs in many heat treatments is required. In this paper, the experimental techniques developed to quantify the temperature fields during quenching and to quantify the residual stresses in the quenched part are presented. The temperature fields were quantified using thermocouples embedded in the components. The residual stresses were quantified using a newly developed strain gauging, sectioning and dynamic data acquisition technique. The techniques were verified using thermal histories and residual stresses for an engine cylinder head quenched at two different quenchant temperatures. The measurements obtained were incorporated into an analytical program (finite element) to study the resi dual stresses produced during the quenching process. Good correlation between the experimentally measured residual stress and the analytical predictions was demonstrated. INTRODUCTION The cylinder head is a complicated engineering structure subjected to many complex thermal-mechanical loading conditions. The ultimate reliability and durability of the cylinder head is a function of; the combined thermal and mechanical stresses imposed on it, (one of which is residual stress) [1,2], the mechanical properties, and the operating temperatures it is subjected to in operation. The optimization of this cylinder head is a very challenging engineering problem. An important tool for this design optimization is a robust Finite Element Model (FE) which can predict, with a reasonable accuracy, the cylinder head temperatures and stresses. While finite element analysis is a well-developed tool, its use in the prediction of residual stresses in cast aluminum cylinder heads has not been fully developed