In addition, there was also a desire to optimize the design to minimize residual stresses. To obtain the required material properties for certain engine types in production, design changes were investigated to make the cylinder frame easier to cast. As a result of this and further successful validation efforts, this new time-dependent plasticity model will be made publicly available in MAGMA5 Rel. This was a key to success, as MDT found that the stress levels actually observed were predictable with MAGMASOFTВ® when considering creep effects occurring during the slow cooling of the casting in the mold. In this context, MDT and MAGMA worked together to verify new capabilities of a visco-elasto-plastic material model for MAGMAstress. This approach is well suited for materials with coarse structures, such as cast iron. In order to ensure that the residual stress results from MAGMASOFTВ® give the correct picture of the stress situation, MDT initially performed residual stress measurements on actual cylinder frames using the ring core measurement method. To identify the endangered areas and validate design and process changes, MDT uses MAGMASOFTВ®. The functionality dictates the geometry and requires changing wall-thicknesses, sometimes leading to crucial stress situations. These frames are sand cast in GJL-250 gray iron or GJS-500 ductile iron and weigh up to 40 tons. This is a problem that MDT quality management is eager to avoid before it occurs, as the fallout is very hard to deal with.ДЄn example for this are the cylinder frames for the two-strike-engines. In some cases and under certain conditions, residual stresses can sum up to problematic amounts and result in a shortened engine lifetime. To ensure longevity, MDT is always looking to minimize residual stresses in the component. This marks them as being known to carry an important function and to present manufacturing challenges, often with regard to castability and durability. Many of the cast parts are classified as a вЂњcontrolled componentвЂќ. Materials range from steel to CGI, providing the required material properties such as sufficient strength and good heat transfer. Roughly 30% of the mass of a two-stroke engine is made of cast components, and on the smaller bore four-stroke engines, the entire frame structure is cast in one piece. The component list of a diesel engine includes a large number and variety of castings such as liners, bearing caps and cylinder frames. In 2014, around 48 000 ships transported more than half of the worldвЂ™s commercial goods across the oceans propelled by MDT two- and four-stroke diesel engines, with a power output of up to 87 MW. MAN Diesel Technology (MDT) engines have been renowned for their quality for decades.

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