Compared with traditional liquid and solid processing methods, semi-solid die casting process can apparently overcome shrinkage cavity and porosity defects in castings and high deformation resistance and high residual stress shortcomings in forging parts. Semi-solid die casting process with advantages such as high efficiency and low cost, will become the optimal process for high quality automobile parts. In this study, using the clamp as an example, the author introduced product structure optimization and die design for semi-solid die-casting process of aluminum alloy in a new product development.The Computer Aided Engineering technology was applied to the product structure optimization according to the stress analysis. The optimal mold structure, including cavity layout, gating system, overflow and vent systems, were confirmed based on the die design criteria for traditional die casting, combining with the characteristics of semi-solid forming and the simulation results. The semi-solid aluminum alloy clamp parts with excellent performances were finally developed successfully by means of product structure optimization, die design, parameters optimization of die casting process, and the mechanical properties test of products.The existing parts were optimized to make them more suitable for semi-solid die casting processing. In addition, a reasonable die design specially for semi solid processing was an important guarantee for a successful semi solid product applied in industry. Computer numerical simulation was applied in product structure design for semi-solid die casting, die design, die-casting process optimization and other aspects, to shorten the development cycle of new product, reduce cost and improve efficiency.
