J. Phys. IV France
Volume 120, December 2004
Page(s) 761 - 768

J. Phys. IV France 120 (2004) 761-768

DOI: 10.1051/jp4:2004120088

Mechanical effects of water quenching on aluminum automotive parts

P. Auburtin, N. Morin and C. Pille

PSA Peugeot Citroën, Route de Gisy, 78943 Velizy-Villacoublay, France

Computer modeling is nowadays necessary in order to achieve proper automotive components in short development times and low costs. To reach the required high accuracy, process and manufacturing operations, such as heat treatments, must be included in simulations. Indeed, they generate residual stresses, which strongly influence high cycle fatigue life, as well as geometrical distortions, which need to be evaluated and corrected in order to manufacture parts within the proper dimensional tolerances. Recent developments undertaken at PSA Peugeot-Citroën have enabled the development of a methodology to evaluate the residual stresses and distortions generated during T6-T7 heat treatment of aluminum automotive components. The calculation with Abaqus finite element software, developed on a cylinder head, follows 2 different steps: a thermal analysis and a mechanical analysis. The comparison between the simulation results and experimental measures is encouraging. Moreover, coupled with high cycle fatigue life, failures encountered during engine tests can be now explained. The methodology has also been applied on other aluminum automotive components, such as cast alloy wheels and engine cradles.

© EDP Sciences 2004