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Keywords = crossbeam casting

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16 pages, 4016 KB  
Article
Numerical Simulation and Experimental Validation of Residual Stress in Heavy Machine Tool Crossbeam Casting During Demolding
by Jingfan Cheng, Yiqi Zhang and Dunming Liao
Metals 2025, 15(7), 687; https://doi.org/10.3390/met15070687 - 20 Jun 2025
Viewed by 1130
Abstract
This study investigates a heavy-duty CNC machine tool crossbeam casting manufactured by a leading heavy machine tool producer. A numerical simulation model for the demolding process was developed using proprietary Computer-Aided Engineering (CAE) software. The experimental validation of the residual stress was performed [...] Read more.
This study investigates a heavy-duty CNC machine tool crossbeam casting manufactured by a leading heavy machine tool producer. A numerical simulation model for the demolding process was developed using proprietary Computer-Aided Engineering (CAE) software. The experimental validation of the residual stress was performed using the blind-hole method on the guide rail mounting surface. The simulation results were compared with experimental data, revealing that the post-demolding simulations exhibited smaller fluctuations than the pre-demolding predictions. The maximum principal stress prediction resulted in an absolute error of 11.8%, effectively reflecting the residual stress distribution for casting design and production optimization. Full article
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25 pages, 64797 KB  
Article
Deck Slab Elements for the Accelerated Construction of Steel–Concrete Composite Bridges
by Franz Untermarzoner, Johann Kollegger, Michael Rath, Kerstin Gaßner and Tobias Huber
Appl. Sci. 2023, 13(13), 7825; https://doi.org/10.3390/app13137825 - 3 Jul 2023
Cited by 2 | Viewed by 10081
Abstract
Various methods have been developed to produce deck slabs for steel–concrete composite bridges. Usually, the deck slabs are cast with in situ concrete using a formwork carriage, resulting in construction progress of 15 to 25 m of deck slab per week. A new [...] Read more.
Various methods have been developed to produce deck slabs for steel–concrete composite bridges. Usually, the deck slabs are cast with in situ concrete using a formwork carriage, resulting in construction progress of 15 to 25 m of deck slab per week. A new construction method was developed at the Institute of Structural Engineering (TU Wien), which enables the swift erection of the concrete deck slab. This method employs precast deck slab elements with reinforced concrete cross-beams which span in the transverse direction. With this new construction method, producing up to two deck slab sections of 15–25 m per day becomes possible. Further, the performance of novel reinforcement detailing required for the precast deck slab elements is investigated by structural testing. The experiments consist of eight load-bearing tests on four specimens which represent sections of the element during casting and after completion. The investigated parameters in series 1 are the length and spacing of loops, used for protruding longitudinal bars enclosure. In series 2, the enclosure of the shear reinforcement and the height of the cross beams are varied. The results show that the targeted bending capacity could be reached in all tests with no signs of premature failure due to detailing reasons. Based on the experimental results, the feasibility of the new approach is shown and recommendations for detailing are given. Full article
(This article belongs to the Section Civil Engineering)
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21 pages, 15759 KB  
Article
Experimental and Numerical Study of an Automotive Component Produced with Innovative Ceramic Core in High Pressure Die Casting (HPDC)
by Giovanna Cornacchia, Daniele Dioni, Michela Faccoli, Claudio Gislon, Luigi Solazzi, Andrea Panvini and Silvia Cecchel
Metals 2019, 9(2), 217; https://doi.org/10.3390/met9020217 - 12 Feb 2019
Cited by 9 | Viewed by 7035
Abstract
Weight reduction and material substitution are increasing trends in the automotive industry. High pressure die casting (HPDC) is the conventional casting technology for the high volume production of light alloys; it has recently found wide application in the manufacturing of critical components, such [...] Read more.
Weight reduction and material substitution are increasing trends in the automotive industry. High pressure die casting (HPDC) is the conventional casting technology for the high volume production of light alloys; it has recently found wide application in the manufacturing of critical components, such as complex and thin geometry automotive parts. However, the major restriction of this affordable technology is the difficulty to design and realize hollow sections or components with undercuts. An innovative way to further increase the competitiveness of HPDC is to form complex undercut shaped parts through the use of new lost cores that are able endure the high pressures used in HPDC. This paper investigates the use of innovative ceramic lost cores in the production of a passenger car aluminum crossbeam by HPDC. Firstly, process and structural simulations were performed to improve the crossbeam design and check the technology features. The results led to the selection of the process parameters and the production of some prototypes that were finally characterized. These analyses demonstrate the feasibility of the production of hollow components by HPDC using ceramic cores. Full article
(This article belongs to the Special Issue Material and Process Design for Lightweight Structures)
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