Simulation analysis of thermal stress during casting process of large-sized alloy steel ingot

To quantitatively analyze the main reasons of common crack in the surface of alloy steel ingot with 5%Cr during production and to propose the direction of improvement, a physical model system, which consisted of steel ingot mold, casting, riser of heat insulation, slag layer, sprue pipe, and runner, was primarily established by three-dimensional CAD software. The joint simulation method concerned with pouring, solidification, temperature field, and cast stress was determined by using ADSTEFAN cast simulation software. The stress distribution of casting and the quantitative effect of shake-out timing were analyzed in detail. An effective plan of decreasing stress was proposed in cooling mode. © Higher Education Press and Springer-Verlag 2009.