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Procedia Engineering 136 (2016) 28 – 32

The 20th International Conference: Machine Modeling and Simulations, MMS 2015

Comparison of numerical analysis of stress-strain states of cast iron

with vermicular graphite shape and globular graphite shape
Petra Kováčikováa,*, Radka Bezdedováa, Ján Vavro, jr.a, Ján Vavroa
a
Alexander Dubček University of Trenčín, Faculty of Industrial Technologies in Púchov, I. Krasku 491/30, 020 01 Púchov, Slovakia

Abstract

Method of final elements is highly effective modern numerical method for solving technical and scientific tasks, which is
nowadays more and more used. The report deals with comparison of analysis of stress conditions on microstructure of cast iron
with vermicular graphite and with cast iron type with globular graphite. Briefly describes their chemical composition, mechanical
properties and structure that we will serve us as input parameters for the creation of computational modeling and numerical
analysis. Model of structure for the computer simulation was created in two-dimensional field by linear triangular elements for
both types of graphitic cast iron. The size of elements was determined based on sensitivity analysis. According to the real
structure of cast iron with vermicular shape of graphite and cast iron with globular graphite will be created model from which
will be performed numerical analysis of voltage-strain states by finite element method – FEM software system ADINA 8.8.0.
This calculation program helps to solve a very difficult task and has the advantage that the generated model can reflect very well
the actual geometry of the object.
© 2016
© 2016TheTheAuthors.
Authors.Published
Publishedby by Elsevier
Elsevier Ltd.Ltd.
This is an open access article under the CC BY-NC-ND license
Peer-review under responsibility of the organizing committee of MMS 2015.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of MMS 2015
Keywords: iron; numerical analysis; vermicular graphite; computational modelling; structure model

1. Introduction

Modern programs provide almost complete service, whether from the point of view of materials, mechanics,
technology or other areas related to the execution of engineering work. The article is focused on comparison of
tension conditions numerical analysis of graphitic cast iron with vermicular shape of graphite and cast iron with

* Corresponding author. Tel.: +421 42 2851 881.

E-mail address: petra.kovacikova@fpt.tnuni.sk

1877-7058 © 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of MMS 2015
doi:10.1016/j.proeng.2016.01.169
 Petra Kováčiková et al. / Procedia Engineering 136 (2016) 28 – 32 29

globular shape of graphite. It briefly described their chemical composition, structure and mechanical qualities.
Through the image analysis was on samples evaluated the amount of graphite elements, content and its shape. Such
processed results were used as input parameters for tension analysis in vicinity of graphitic elements by means of the
model of final elements method and program ADINA.

2. Material characteristics of cast iron with vermicular and globular graphite

Elements of graphite in vermicular cast iron are longwise, cannot have sharp edges and their orientation is
random. In the Fig.1, we can see particular elements of graphite with vermicular and globular shape in the 2-D view.
At the same time, we can see that the part of graphite is excreted in the form of small globules. The amount of
globular graphite is called as nodularity. The specific shape of vermicular graphite with a good adhesion to the own
metal matrix ensures the increase of mechanical qualities (Table 1). Chemical composition of input smelt is
common for cast iron with vermicular and globular shape of graphite (Table 2) [1, 2].

Fig. 1. Microstructure of cast iron with spheroidal and vermicular-type graphite, zoomed 100u.

Table 1. Mechanical properties of cast iron with vermicular and globular type graphite.
Properties Unit Vermicular graphite Globular graphite
Tensile strength Rm MPa 300 – 550 380 – 900
Contractual yield strength Rp0,2 MPa 250 – 380 250 – 600
Compression strength Rmt MPa 600 – 1200 600 – 1200
Ductility A % 2–8 2 – 25
Hardness HB – 130 – 280 120 – 350
Fatigue strength MPa 120 – 180 150 – 310
Elastic modulus E kN.mm–2 130 – 160 140 – 185

Table.2. Chemical composition of initial melts for both cast (%).

C Si Mn P S
3.4 – 3.8 2.4 – 2.7 max 0.6 max 0.06 max 0.02

3. Quantitative metallography

For shooting, digital processing of the scene and measurement of structural parameters was used the program
LUCIA. On non-etched samples were by help of image analysis obtained input parameters for numerical analysis.
Microstructure of prepared samples was filmed by the microscope´s camera and the scene was transferred into the
30 Petra Kováčiková et al. / Procedia Engineering 136 (2016) 28 – 32

computer. From the record of the scene were defined graphite elements – threshold method. From the scene were
then excluded inclusions and after setting the structural parameters was carried out the evaluation. This procedure
was carried out for cast iron with vermicular and cast iron with globular shape of graphite. From recorded values
were obtained following data: amount of elements, shape and content of graphite. For fast graphite shape evaluation
is recommended the factor (1):

ସగǤ஺
ܵൌ (1)
௉మ

where A is the area of elements and P is the perimeter of elements. Shape factor has values [3]:

• for sliced graphite S < 0.1

• for vermicular graphite S (0.1 – 0.5)
• for globular graphite S > 0.5

In contrast to globular shape of graphite were found elements of graphite in morphology of cast iron with
vermicular graphite, characterized by wide range of values of shape factors. Presented method of quantitative
evaluation of shape is usable for sliced, worm, imperfectly grainy and regularly grainy; in limited scale for
spiderlike or flaky graphite [2, 3].

4. Numerical analysis of tension conditions

Solution of mathematical model replaces the experiment on a real system – simulation. Examined issue is
analyzed deterministically, also with the usage of numerical methods. Model solution is carried out by means of
program system. An important factor by problem modeling if tension conditions and their evaluation in by us
selected program ADINA, is the network density and the type of applied element. By calculating model was carried
out the sensitivity analysis on change of tension size allocation in vicinity of graphitic element. On the basis of
sensitivity analysis we have set the size of elements of 0.0005 mm. By determined elements´ size is reached the
sufficient accuracy of solution, in which the deviation does not exceed 2.5%.

5. Geometric model formation for numerical analysis

For elements of vermicular and globular shape and for quality evaluation of graphitic element was necessary to
determine geometric characteristics, which will describe such element. Exact description of graphitic elements
boundaries will be obtained during the evaluation of results of FEM analysis. Such partial limitation is due to our
inability to obtain another description of boundary, than by final elements network (Fig. 2 and Fig. 3). The shape of
graphitic element has the significant influence on size of own frequencies, as well as on tension condition in its
vicinity. If we want to evaluate the quality of graphitic element, we need to determine geometric characteristics
describing this element. Acquired characteristic data from optical analysis of the scene will serve as input
parameters. Matrix was considered as homogeneous structure with linear dependence of deformation-tension.
Graphitic element for vermicular and globular shape represents the cavity, which will be modeled in the way that on
its place will not form the final elements network. Such modeling of graphitic elements is admissible in regards to
their qualities, such as low pull solidity and frequent de-cohesion from the matrix [4, 5].
 Petra Kováčiková et al. / Procedia Engineering 136 (2016) 28 – 32 31

Fig. 2. Generated mesh for one particle with vermicular shape.

Fig. 3. Generated mesh for one particle with spheroidal shape.

Approach to the solved issue was similar to the plane level task. As input parameters for numerical analysis were
defined edge conditions. Latitude degrees were eliminated along the entire perimeter of the model. Use is linear
material model Young´s modulus of elasticity E = 1.59 e-5 MPa, Poisson´s number υ = 0.26 and material density
ρ = 7100 kg.m-3. Size of solution area for one vermicular graphitic element is 1 u 1 mm. Tension allocation in the
vicinity of vermicular shape element is displayed in the Fig. 4 and in the area of the globular shape element in
the Fig. 5.

Fig. 4. The distribution of stress around graphitic particle with vermicular shape.
32 Petra Kováčiková et al. / Procedia Engineering 136 (2016) 28 – 32

Fig. 5. The distribution of stress around graphitic particle with spheroidal shape.

6. Conclusion

From results of the analysis it is clear that the shape of graphitic element has an important influence on the size of
own frequencies, as well as on the condition of tenseness in its vicinity. Graphitic elements cause in the matrix
tension concentration. The size of tension concentration will depend on the shape of graphitic elements. According
to results, we can say that tension concentration is increased by irregularity of graphitic element. Numerical analysis
of tension conditions of cast iron with vermicular shape of graphite was solved by a method of final elements in the
program ADINA. FEM model was created on the basis of microstructure evaluation and image analysis. Results of
analyzes can provide initial information about qualities of the system or structure of the material even before the
technological processing in the practice.

Acknowledgement

This work was supported by the VEGA grant No. 1/0385/14, KEGA No. 007TnUAD-4/2013 and KEGA grant
No. 006TnUAD-4/2014.

References

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[3] A. Vaško, P. Skočovský, Quantitative evaluation of the cast iron structure, EDIS, University of Žilina, 2007, ISBN 978-80-8070-748-4.
(in Slovak)
[4] J. Vavro, H. Hajská, J. Vavro jr., A. Vavrová, New methods and approaches of experimental mechanics in identifying defects and failures in
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