Evolution analysis of process-induced residual stress during the manufacture of diesel engine block

Residual stress is most likely to cause deformation in a diesel engine block (DBs). The traditional independent analysis method is no longer suitable for obtaining the residual stress of multi-process diesel engine blocks (DBs), because the stress is constantly produced and changed during the casting, heat treatment, and cutting processes. Therefore, an evolution analysis method (EAM) is proposed. First, an evolution analysis model of a diesel engine block (DBs) was established. Subsequently, the residual stress of the diesel engine block (DBs) in the casting and heat treatment processes was analyzed using ProCAST and ABAQUS. Finally, the material removal of the diesel engine block (DBs) during the machining process was simulated by using ABAQUS. The residual stresses for every process were calculated by coupling inherited and process-induced stresses. Thus, the final stress distribution of the diesel engine block (DBs) was deduced by considering the entire machining process. The evolution analysis of the residual stress is significant for controlling the deformation of the diesel engine block (DBs).