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<p>During the casting formation process of shearer rocker arm housings, excessive residual stresses are prone to develop, which may induce metal fatigue in the housing components and consequently compromise their in-service performance. To reduce residual stresses and improve casting quality, this study investigates the influence of shake-out temperature on residual stress distribution through an integrated approach combining ProCAST numerical simulation and blind-hole drilling experimental measurements. The study first predicted the residual stress distribution through numerical simulation, followed by experimental validation using the blind-hole drilling method on actual castings. Comparative analysis revealed a maximum relative error of 9.66% and an average error of 5.24%, confirming the accuracy of the simulation model. Further analysis was conducted to investigate the effects of different shake-out temperatures (700&#xa0;°C, 800&#xa0;°C, 900&#xa0;°C) on residual stress characteristics. The results demonstrate that lower shake-out temperatures effectively reduce residual stresses but simultaneously significantly increase thermal stress prior to shake-out. For complex castings like rocker arm housings featuring substantial geometric variations and wall thickness differences, optimal shake-out temperature selection requires careful balancing between residual stress control and thermal stress management.</p>

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Casting Process Simulation and Residual Stress Analysis of Shearer Rocker Arm Housing

  • 期刊论文

  • 发表日期：

    2025年7月9日

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  • Guochao Zhao,
  • Kaiyu Wang,
  • Yiming Zhang,
  • Guoqiang Zhou

摘要

During the casting formation process of shearer rocker arm housings, excessive residual stresses are prone to develop, which may induce metal fatigue in the housing components and consequently compromise their in-service performance. To reduce residual stresses and improve casting quality, this study investigates the influence of shake-out temperature on residual stress distribution through an integrated approach combining ProCAST numerical simulation and blind-hole drilling experimental measurements. The study first predicted the residual stress distribution through numerical simulation, followed by experimental validation using the blind-hole drilling method on actual castings. Comparative analysis revealed a maximum relative error of 9.66% and an average error of 5.24%, confirming the accuracy of the simulation model. Further analysis was conducted to investigate the effects of different shake-out temperatures (700 °C, 800 °C, 900 °C) on residual stress characteristics. The results demonstrate that lower shake-out temperatures effectively reduce residual stresses but simultaneously significantly increase thermal stress prior to shake-out. For complex castings like rocker arm housings featuring substantial geometric variations and wall thickness differences, optimal shake-out temperature selection requires careful balancing between residual stress control and thermal stress management.