Effect of Plunger Speed and Solid Fraction on Automotive Component by Thixoforming Simulation

2020 ◽  
Vol 17 (2) ◽  
pp. 7942-7955
Author(s):  
M.R. Mohamad Kamal ◽  
N.F. Bazilah ◽  
N.F. M. Pzil ◽  
M.H. Idris ◽  
M.S. Salleh ◽  
...  
Keyword(s):  
Solid Fraction ◽  
Solidification Rate ◽  
Solid Content ◽  
Simulation Software ◽  
Forming Process ◽  
3D Cad ◽  
Alloy Az91d ◽  
Metal Forming Process ◽  
Thixotropic Behaviour ◽  
Semi Solid

Thixoforming is a promising metal forming process to produce near net-shape components with high casting quality. Thixoforming of metallic alloy utilizes the thixotropic behaviour of the material with near globular or globular microstructure in the semi-solid condition. The solid content is between 50% to 70% before forming. In this paper, the effect of plunger speed and a solid fraction on an alternator housing was investigated by advance casting simulation software. The 3D CAD model of the alternator housing was created using SolidWorks software and AnyCasting software is utilized for the simulation of the thixoforming parameter and magnesium alloy (AZ91D) is the material used. The simulation had been done by varying the plunger speed, temperature (solid fraction) of the material, and both Power Law and Bingham Viscosity model are used in the simulation to identify the defect prediction at the end. The simulation result shows that laminar filling in semi-solid slurry able to achieved by controlling the plunger speed and temperature. Slower speed and lower melt temperatures are preferable in thixoforming. Therefore, a solid fraction of the material, plunger speed, and solidification rate do influence the filling behaviour of the casting of semi-solid metal.

Wrinkling Prediction and Optimization of Sheet Metal Forming Process by Numerical Simulation

2015 ◽  
Vol 818 ◽  
pp. 252-255 ◽  
Author(s):  
Ján Slota ◽  
Marek Šiser
Keyword(s):  
Numerical Simulation ◽  
Material Model ◽  
Mechanical Tests ◽  
Simulation Software ◽  
Forming Process ◽  
Part Geometry ◽  
Nominal Thickness ◽  
430 Stainless Steel ◽  
Metal Forming Process ◽  
Aisi 430

The paper deals with optimization of forming process for AISI 430 stainless steel with nominal thickness 0.4 mm. During forming of sidewall for washing machine drum, some wrinkles remain at the end of forming process in some places. This problem was solved by optimization the geometry of the drawpiece using numerical simulation. During optimization a series of modifications of the part geometry to absolute elimination of wrinkling was performed. On the basis of mechanical tests, the material model was created and imported into the material database of Autoform simulation software.

EN AC-46500 Injected by Semi-Solid Rheocasting

2008 ◽  
Vol 141-143 ◽  
pp. 283-288 ◽  
Author(s):  
Manel Campillo ◽  
Maite T. Baile ◽  
Sergi Menargues ◽  
Antonio Forn
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
High Pressure ◽  
Structural Integrity ◽  
Tensile Tests ◽  
Simulation Software ◽  
Industrial Plant ◽  
Forming Process ◽  
Die Cast ◽  
Semi Solid

EN AC-46500 aluminium components are formed by Semi-Solid Rheocasting (SSR) in an industrial plant using a 700 tons high pressure machine. The dies wear was designed by the PLCO model of the ProCast simulation software. The components have had a good structural integrity and the mechanical properties after T6 treatment have been equivalent to that obtained by the same alloy by die cast. The present work describes the SSR forming process, the resulting microstructure as well as the optimization of the ageing heat treatment by hardness evolution. The results of the tensile tests make these clear.

Effect of Solid Fraction on Microstructure and Casting Faults of AZ91D Alloys in New Type Semi-Solid Injection Process

2006 ◽  
Vol 116-117 ◽  
pp. 441-444 ◽  
Author(s):  
Kenji Miwa ◽  
Rudi S. Rachmat ◽  
Takuya Tamura
Keyword(s):  
Solid Fraction ◽  
Testing Machine ◽  
Solid Particles ◽  
Casting Defects ◽  
Permanent Mold ◽  
Forming Process ◽  
Injection Process ◽  
Controlling System ◽  
New Type ◽  
Semi Solid

We have developed new type semi-solid injection process, that is, runner-less injection process. In order to investigate the effects of solid fraction on microstructure and casting defects of AZ91D in new type semi solid injection process, semi-solid forming testing machine which has the same system as a runner-less injection machine has been made on an experimental basis. Its temperature controlling system has been established to obtain the homogeneous solid-liquid coexisted state in its injection cylinder. AZ91D billets are injected into a permanent mold by this machine in the semi-solid state. A shearing in the part of nozzle of injection cylinder is the most important to reveal thixotropic property of alloy slurry in semi solid forming process by injection machine. So it needs controlling of solid fraction to affect thixotropic property. In order to decrease casting defects and hold homogeneous structure, solid fraction more over 50% is needed. But when the solid fraction increases more than 50%, primary solid particles grow coarser, and then controlling method is required to suppress coarsening. In the case of less than 50% of solid fraction, liquid part preferentially fills inside the permanent mold and alloy slurry continue to fill the mold behind alloy liquid. Then large casting defects form at the boundary of both flows.

Prediction of Rupture in Gas Forming Process Using Continuum Damage Mechanic

2012 ◽  
Vol 463-464 ◽  
pp. 1047-1051
Author(s):  
M. Rahafrooz ◽  
M. Sanjari ◽  
M. Moradi ◽  
Danial Ghodsiyeh
Keyword(s):  
Metal Forming ◽  
Damage Mechanics ◽  
Damage Model ◽  
Simulation Software ◽  
Ductile Damage ◽  
Continuum Damage ◽  
Forming Process ◽  
Continuum Damage Mechanic ◽  
Damage Mechanic ◽  
Metal Forming Process

The Continuum Damage Mechanics is a branch of applied mechanics that used to predict the initiation of cracks in metal forming process. In this article, damage definition and ductile damage model are explained, and also ductile damage model is applied to predict initiation of fracture in gas metal forming process with ABAQUS/EXPLICIT simulation. In this method instead of punch, the force is applied by air pressure. In this study, first the ductile damage criterion and its relations are taken into account and, subsequently, the process of gas-aid formation process is put into consideration and ductile damage model for prediction of rupture area is simulated using ABAQUS simulation software. Eventually, the process of formation via gas on the aluminum with total thickness of 0.24 [mm] was experimentally investigated and the results acquired from experiment were compared with relating simulations. The effect of various parameters such as radius of edge matrix, gas pressure and blank temperature has been evaluated. Simulation was compared with experimental results and good agreement was observed.

Industrial Applications of Rheoforming Technology in China

2012 ◽  
Vol 192-193 ◽  
pp. 36-46
Author(s):  
W.C. Keung ◽  
Xiang Jie Yang ◽  
Wei Wei Shan
Keyword(s):  
Metal Forming ◽  
Academic Research ◽  
Industrial Applications ◽  
Solid Metal ◽  
Current Status ◽  
Forming Process ◽  
Metal Forming Process ◽  
Semi Solid ◽  
China Mainland ◽  
Rheological Forming

Rheological forming, a semi-solid metal forming process, is one of the manufacturing technologies for near net shape forming. The technology has attracted global academic research interests in recent years. This paper presents the current status of industrial applications of the semi-solid rheological forming technology in the China mainland. A variety of semi-solid slurry preparation techniques have been adopted including electromagnetic stirring and low superheat pouring. Dedicated semi-solid rheological forming equipment developed by the local manufacturers have been highlighted. This paper also makes an attempt to review the crucial factors for successful industrial application of the semi-solid metal forming process.

Semi-Solid Forging Process and Die Design in the Production of Aluminum Thin Plates

2014 ◽  
Vol 217-218 ◽  
pp. 151-158 ◽  
Author(s):  
Chul Kyu Jin ◽  
Chung Gil Kang
Keyword(s):  
Thin Plate ◽  
Solid Fraction ◽  
Hydraulic Press ◽  
Die Design ◽  
Thin Plates ◽  
Forming Process ◽  
Fluid Analysis ◽  
A356 Aluminum ◽  
Semi Solid ◽  
Solid Forging

In this study, A356 aluminum thin plates (1.2 mm thick) are fabricated using the semi-solid forming process. Using the electromagnetic stirrer, A356-based semi-solid slurry is fabricated. The configuration of the thin die cavity for forging is designed using the fluid analysis of MAGMA software. The dimension of the thin plate is 150 x 150 x 1.2 mm. The semi-solid slurry with 45% solid fraction is created and then injected into the forging die at the 200-ton hydraulic press for compression. Thin plate with semi-solid slurry at 45% of the solid fraction (fs) is fabricated with punch speed of 300 mm/s and punch pressure of 200 MPa for compression the slurry. The formability, mechanical properties and microstructure of a formed thin plate sample are analyzed. As a result, a thin plate with 211.5 MPa of tensile strength and 8.5% of elongation can be formed.

Semi-Solid Processing of Aluminium and High Melting Point Alloys

1993 ◽  
Vol 207 (1) ◽  
pp. 1-8 ◽  
Author(s):  
P Kapranos ◽  
D H Kirkwood ◽  
C M Sellars
Keyword(s):  
Mechanical Properties ◽  
Metal Forming ◽  
Cast Alloy ◽  
High Melting Point ◽  
Forming Process ◽  
Stellite 21 ◽  
Complex Shapes ◽  
Metal Forming Process ◽  
Semi Solid ◽  
Conventionally Cast

Thixoforging (a semi-solid metal-forming process) of non-dendritic A357 aluminium alloy has been studied to assess the effects of process variables on the component integrity. Complete filling of the dies required ram velocities in excess of 300 mm/s and centre-line porosity in the thixoforged components was reduced by ram loads up to 55 kN. The mechanical properties of these thixoforgings were superior to conventionally cast alloy. Some work has also been carried out on M2 tool steel and Stellite 21 to demonstrate that these alloys may be thixoforged to complex shapes with good mechanical properties.

Prediction of Springback of the One-Axle Rotary Shaping Based on Artificial Neural Network

2013 ◽  
Vol 535-536 ◽  
pp. 318-321
Author(s):  
Xia Jin ◽  
Shi Hong Lu
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Simulation Software ◽  
Forming Process ◽  
Training Samples ◽  
Metal Forming Process ◽  
Artificial Neural ◽  
Artificial Neural Network Ann ◽  
Set Up ◽  
The One

One-axle rotary shaping with the elastic medium (RSEM) is a kind of advanced sheet metal forming process. The research object is the springback of aluminous U-section. The orthogonal method is used to arrange the simulation experiments, the forming and springback of the workpiece are simulated successfully with the Finite Element Simulation software, and The main factors influenced the RSEM are analyzed. The simulation results are used as the training samples of the artificial neural network (ANN), and the ANN prediction model of RSEM process is set up. The prediction results would be tested with the experiment data, and only a little tolerance was existed between the two values. It demonstrated that the combination of orthogonal test, numerical simulation and neural network could effectively predict the springback of RSEM, the design efficiency of process parameters would be improved. It would guide the development of precision forming technology.

Modeling of the Semi-Solid Material Behavior and Analysis of Micro-/Mesoscale Feature Forming

2006 ◽  
Vol 129 (2) ◽  
pp. 237-245 ◽  
Author(s):  
Gap-Yong Kim ◽  
Muammer Koç ◽  
Rhet Mayor ◽  
Jun Ni
Keyword(s):  
Solid Fraction ◽  
A356 Alloy ◽  
Structural Evolution ◽  
Solid Material ◽  
Material Behavior ◽  
Flow Rule ◽  
Stress Model ◽  
Forming Process ◽  
Mesoscale Feature ◽  
Semi Solid

One of the major challenges in simulation of semi-solid forming is characterizing the complex behavior of a material that consists of both solid and liquid phases. In this study, a material model for an A356 alloy in a semi-solid state has been developed for high solid fractions (>0.6) and implemented into a finite element simulation tool to investigate the micro-/mesoscale feature formation during the forming process. Compared to previous stress models, which are limited to expressing the stress dependency on only the strain rate and the temperature (or the solid fraction), the proposed stress model adds the capability of describing the semi-solid material behavior in terms of strain and structural evolution. The proposed stress model was able to explain the strain-softening behavior of the semi-solid material. Furthermore, a simulation model that includes the yield function, the flow rule, and the stress model has been developed and utilized to investigate the effects of various process parameters, including analysis type (isothermal vs nonisothermal), punch velocity, initial solid fraction, and workpiece shape (“flat” versus “tall”) on the micro-/mesofeature formation process.

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