Comparison of residual stresses in sand- and chill casting of ductile cast iron wind turbine main shafts

Mads Rostgaard Sonne, J. O. Frandsen, Jesper Henri Hattel

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    Abstract

    In this work, simulations of pouring, solidification and cooling, and residual stress evolution of sand and chill cast wind turbine main shafts is performed. The models are made in the commercial software MAGMAsoft. As expected, the cooling rate of the sand casting is shown to be much lower than for the chill casting, resulting in a very course microstructure.From the simulations the nodule count is found to be 17 nodules per mm2 and 159 nodules permm2 for the sand and chill casting, respectively, in the critical region of the main bearing seat.This is verified from nodule counts performed on the real cast main shafts. Residual stressevaluations show an overall increase of the maximum principal stress field for the chill casting,which is expected. However, the stresses are found to be in compression on the surface of thechill cast main shaft, which is unforeseen.
    Original languageEnglish
    Article number012025
    JournalI O P Conference Series: Materials Science and Engineering
    Volume84
    Number of pages10
    ISSN1757-8981
    DOIs
    Publication statusPublished - 2015
    Event14th International Conference on Modelling of Casting, Welding and Advanced Solidification Processes - Awaji island, Hyogo, Japan
    Duration: 21 Jun 201526 Jun 2015
    http://mcwasp2015.jp/

    Conference

    Conference14th International Conference on Modelling of Casting, Welding and Advanced Solidification Processes
    Country/TerritoryJapan
    CityAwaji island, Hyogo
    Period21/06/201526/06/2015
    Internet address

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