Numerical simulation of residual stresses for a brake disc casting

The numerical modelling of residual stresses prediction model for a brake disc is presented in this paper. The goal is to conduct numerical experimentation to reduce the residual stresses of the brake disc casting to obtain better casting quality. Computer-aided engineering software based on the finite element method is also employed in this study. Numerical simulations were conducted for the brake disc casting with different shake-out times. The solidification phenomena were examined to observe distribution of residual stresses and the optimised shake-out time was then proposed based on the simulated results to alleviate residual stresses of the brake disc casting. Experimentation procedures were also conducted to measure residual stresses of the brake disc casting. The predictions of residual stresses were validated by comparison with experimental measurements and consistency was found between the two results.