Method for relieving residual stress in cast-in-place liners of HPDC engine blocks
A method for relieving residual stress in cast-in-place liners of high pressure die cast (HPDC) engine blocks to prevent cracking in the liners during the machining process. The method includes locally heating up the liners and the surrounding engine block material through rapid induction heating and then cooling down the liners and surrounding engine block material with still ambient air to a predetermined temperature after the residual stress has been reduced to a desired threshold.
1. A method of relieving residual stress in at least one cast-in-place liner of a high pressure die cast engine before machining comprising:
calculating a temperature profile of at least one liner and engine block material surrounding the at least one liner based on material thermoplastic and mechanical properties;
inductively heating the at least one liner and engine block material surrounding the at least one liner;
controlling the inductive heating to obtain the calculated temperature profile of the at least one liner and engine block material surrounding the at least one liner; and
uniformly cooling the at least one liner and engine block material surrounding the at least one liner to a predetermined temperature when a relaxed residual stress is less than or equal to a predetermined relaxed residual stress threshold.
2. The method of claim 1 wherein inductively heating further comprises controlling the inductive heating through at least one adjustable heating path.
3. The method of claim 1 further comprising calculating a residual stress relaxation of the at least one liner and the engine block material surrounding the at least one liner in response to the inductive heating.
4. The method of claim 1 wherein controlling inductive heating further comprises calculating a heating up rate of the at least one liner and engine block material surrounding the at least one liner based on the calculated temperature profile.
5. The method of claim 1 further comprising measuring the relaxed residual stress of the at least one liner and engine block material surrounding the at least one liner.
6. The method of claim 2 further comprising determining the at least one adjustable heating path based on an as cast residual stress distribution of the at least one liner and the engine block material surrounding the at least one liner.
7. A method of relieving residual stress in at least one cast-in-place liner of a high pressure die cast engine before machining comprising:
calculating an as-cast residual stress distribution of the at least one and engine block material surrounding the at least one cast-in-place liner;
calculating a heating up rate and a temperature profile of the at least one liner and engine block material surrounding the at least one liner based on material thermoplastic and mechanical properties;
controlling inductive heating of the at least one liner and engine block material surrounding the at least one liner based on the heating up rate and the temperature profile;
measuring a relaxed residual stress of the at least one liner and engine block material surrounding the at least liner; and
uniformly cooling the at least one and engine block material surrounding the at least one liner to a predetermined temperature when the measured relaxed residual stress is less than or equal to the predetermined relaxed residual stress threshold.
8. The method of claim 7 wherein controlling inductive heating further comprises controlling inductive heating through at least one adjustable heating path based on the as-cast residual stress distribution of the at least one liner and engine block material surrounding the at least one liner.
9. The method of claim 7 wherein uniformly cooling further comprises cooling the at least one and engine block material surrounding the at least one liner in still ambient air.
10. The method of claim 7 wherein uniformly cooling further comprises cooling the at least one and engine block material surrounding the at least one liner in forced warm air.