Casting Geometry - Stress Concentration Analysis

Fatigue Local Stress

• The casting part was evaluated to understand how operational loading generated local stress amplification around junctions, thickness transitions, and geometry features inherent to the casting process. The review concentrated on locating stress levels that could influence fatigue performance, particularly at casting radii, draft transitions, and regions shaped by manufacturing constraints.
  

• A nonlinear analysis was conducted with mesh refinement in high-curvature areas,

  temperature independent properties representative of cast material behaviour, and contact definitions for assembled interfaces; this combination allowed stable calculation of local stress fields around sensitive zones.
  

• The simulation showed elevated stresses along inner corners and abrupt thickness changes typical of cast components, highlighting areas where modest geometric smoothing or gating-related adjustments could improve durability.
  

• These findings offered a clear basis for selective refinement and indicated where production-stage quality checks should focus, supporting reliability improvements without altering the fundamental casting design.