Analytically Analysis Related To Stress Concentration on Casting Material of Flange
Keywords:
Casting Part, Stress Concentration, Kt Factor, Machining process, Cracks, Material GS42crMo4, Numerical AnalysisAbstract
Defect arises in the part of flange shaft (casting) made of material GS42crMo4. After castings were made, they
were inspected in inspection department by visual test and non-destructive test. If casting has minor defect then it could
be repaired. If defect was major then it could not be repaired and casting was rejected. In one particular casting (the
part of flange shaft) the crack was observed at the head, on radius portion, which was major defect. Due to heavy
thickness section at the head side, the smaller radius may shrink. Crack was observed after final machining on radius
portion. It was a blind crack inside the casting product, and it was invisible before machining. It was due to the stress
concentration at the radius portion. So, it could not be repaired by grinding and welding. Due to this major defect the
casting was rejected.
We change the design at the radius portion; because defect was occur at the head of the casting on the radius
portion. In the defective design there were two small radii at the head portion, where stress concentration was more, so
there was a possibility of occurring crack.
Then we change the design by making one big radius instead of two small radiuses, & stress concentration at the
head portion was decreased and so we minimized defect of casting flange.
