Abstract: Based on the numerical simulation of solidification of castings, a thermal stress formula and a thermal crack initiation criterion are established, which suggest that the cracks initiate at the two-thirds thickness of solidified layer from outside of castings. Cast steel wheels whose diameters are 800mm are employed to testify the positions of cracks through thermal elastic-plastic analyses and low magnifying structure observations conventionally. The results show that the numerical prediction of cracks coincides with the measured result, and the cracks do not necessarily follow where the defects such as shrinkage holes and porosities occur. It is also found that surface temperature control is an effective factor to avoid the crack formation.

Key words: solidification, crack initiation, crack prediction