1998 SAE International Congress & Exposition

Feb. 23-26, 1998, Detroit, MI

MOLD FILLING AND SOLIDIFICATION STUDIES OF A GRAY IRON ENGINE BLOCK

O. Gurdogan, V. Rubek, O. Selcuk, J. Haskett, H. U. Akay and F. Cutler

Technalysis Incorporated

Indianapolis, Indiana

H. DeLuca

Chrysler Corporation

Indianapolis, Indiana

Abstract

Chrysler's 2.0-liter/four-cylinder gray iron engine block is modeled using Technalysis' finite element metal casting analysis program PASSAGE®/PowerCAST. The effect of different gating designs are investigated to determine the variations in filling patterns and temperature distributions. The results of the numerical simulations performed are used for evaluating different design situations.

Introduction

Simulation of metal casting processes using computer programs which include flow and phase change effects has gained attention during the recent years. A number of commercial casting analysis codes are now available for foundry engineer's usage. In spite of many advancements in this field during recent years, simulation of engine block remains as one of the most challenging cases due to complexity of its geometry and the need for accurate prediction of flow and heat transfer. In this paper we present our recent experiences gained in modeling of an engine block using the computer program developed at Technalysis.