Düsseldorf, 20-11-08 

Mathematical Strength Validation for Complex Castings

Because of the strict safety requirements applying to heavy-duty engine components, validating their strength is one of the most important tasks of a design engineer, for the serviceability of lightweight components depends on it.  

The Forschungskuratorium Maschinenbau (FKM) has developed a guideline entitled Analytical Strength Assessment of Components in Mechanical Engineering which presents a comprehensive methodology of both static and fatigue-strength validation. It applies to components made of cast iron, steel, and malleable iron that are used in all areas of mechanical and systems engineering. At the same time, it applies analogously to any industry that requires stress-optimised components.  

Based on strength specifications in standards and other regulations, calculations yield the actual stress acting on a component together with the requisite safety factors. While calculations should be based on nominal stresses, local elastic stresses may be considered as well. The guideline is modular and adapted to calculation requirements. As a final result, design engineers will obtain a component that is designed for specific stresses and permanent strength. As, moreover, existing designs can be checked for dimension misfits, the safety of casting components in lightweight construction is assured.  

Presenting this code which applies to the entire mechanical-engineering sector, a reprint that is available free of charge from ZGV – Zentrale für Gussverwendung in Düsseldorf uses iron castings to illustrate the concept of the FKM guideline, enabling casting designers to validate the strength of a component quickly based on local stresses at the point of analysis.  

A reprint from 'konstruieren + giessen ' reports on the subject addressed in this information for the trade press, Mathematical Strength Validation for Complex Castings. 
For more information, please ask for your free copy at (zgv@bdguss.de). 

 

The subjects dealt with in previous ZGV information brochures include

• Permanent-mold Casting – a Highly Diverse Mass-production Process with a Wide Range of Applications
• Rapid Manufacturing Enlarges the Range of Precision-casting Applications
• ADI
• Continuously Cast Iron: Suitable for Many Applicationssts
• Cast Metals for Engine Components are Heavy-duty Specialists
• Bionically Designed Castings with a Great Lightweight and Strength Potential
• Precision Casting – an Economical Solution for Complex Components  
• Austenitic Cast Iron Features Properties for Extreme Applications
• Welding of Castings – an Overview
• High-tech Castings Mirror the Dynamic Development of Wind Power Generation
• Cast Iron with Lamellar Graphite – still the most Frequently Used Cast Iron Material
• Cast Cylinder Heads and Crankcases Offer Versatile Solutions for the Cars of Today and Tomorrow