Die Design for Main Bearing Cap of Engine Block Based Semi-Solid Die Casting Process and the Comparison Analysis with Squeeze Casting Process

2019 ◽  
Vol 285 ◽  
pp. 429-435 ◽  
Author(s):  
Song Chen ◽  
Da Quan Li ◽  
Fan Zhang ◽  
Min Luo ◽  
Xiao Kang Liang ◽  
...  
Keyword(s):  
Squeeze Casting ◽  
Die Casting ◽  
Dendritic Structure ◽  
Casting Process ◽  
Die Design ◽  
Main Bearing ◽  
Block Based ◽  
Semi Solid ◽  
Bearing Cap ◽  
Squeeze Casting Process

There are two new processes to development automobile structural components which have certain thickness. In the present paper, taking a main bearing cap product as an example, analyses die design by comparing the experimental and computational numerical simulation results. For the main bearing cap, product structure and mold design were designed to be suitable for characters of SSM die casting and squeeze process. Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity and solid fraction phase make the flow condition more laminar than liquid squeeze casting with the partial fill experiment. And compared with squeeze casting process, the globular shape grain size is smaller than dendritic structure. And mechanical property result shows that the elongation of SSM die casting can achieve more than twice than squeeze casting.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

Development of Steel Wire Rope – Reinforced Aluminium Composite for Armour Material Using the Squeeze Casting Process

2011 ◽  
Vol 277 ◽  
pp. 27-35 ◽  
Author(s):  
Dwi Rahmalina ◽  
Bondan Tiara Sofyan ◽  
Bambang Suharno ◽  
Eddy S. Siradj
Keyword(s):  
Squeeze Casting ◽  
Steel Wire ◽  
High Carbon Steel ◽  
Casting Process ◽  
Optical Microscope ◽  
Wire Rope ◽  
Aluminium Composite ◽  
Ballistic Properties ◽  
Semi Solid ◽  
Squeeze Casting Process

Steel wire rope – reinforced aluminium composite - has been developed to improve the ballistic properties and mobility of armour material. Critical to obtaining ballistic resistance is that the materials must be sufficiently hard and strong, especially at the surface where a projectile will first make impact. To obtain this resistance, aluminium alloys can be strengthened by adding Cu and Mg. This research studied the ballistic properties of aluminium composites with varied Cu and Mg content. The matrix used in this study was an Al-7Si master alloy with 0.08-1.03 wt. % Mg and 0.05-3.75 wt. % Cu, both independently and in combination. A high carbon steel wire rope was used as strengthening material. The samples were produced through the squeeze casting process with a pressure of 1 MPa at semi-solid melting temperatures of 590-610 °C. The slab was then rolled for 10 % reduction to increase the hardness. Ballistic testing was performed in accordance with ASTM F1233 by using a 9 mm calibre projectile and 900 direction. Micro structural observation was conducted in the as-cast and ballistic samples, performed with optical microscope and scanning electron microscope (SEM). The results showed that squeeze casting may improve interfacial wettability and reduce void. The increase in Mg resulted in the decline of interfacial voids, but Cu addition tended to increase them. The aluminium armour was able to withstand a 9 mm calibre projectile, although some cracks were visible. The wire rope was not effective in stopping the penetration of a 7.62 mm calibre projectile.

Considerations on the Reliability of Advanced Squeeze Casting Process

2012 ◽  
Vol 504-506 ◽  
pp. 361-366
Author(s):  
Mario Rosso ◽  
Ildiko Peter
Keyword(s):  
High Performance ◽  
Fracture Behavior ◽  
Squeeze Casting ◽  
Casting Process ◽  
Standard Samples ◽  
Heat Treated ◽  
Semi Solid ◽  
Non Destructive ◽  
Squeeze Casting Process ◽  
A380 Alloys

This paper presents an analysis of an advanced squeeze casting process suitable for the manufacturing of high performance industrial components more quickly and cheaply. After a short description of the process, some produced components are considered. The components, in A380 alloys, have been T6 heat treated and their soundness has been certified by non destructive tests. All considered components have been designed for advanced application in the automotive field, in particular for quite important sport cars. Standard samples for tensile and impact tests have been machined directly from the previous components. After the execution of the tests the fracture surface of samples has been observed by SEM in order to analyze details and to evaluate the influence of the process and of the alloy on the fracture behavior. On polished transverse sections of samples the microstructure of the alloy has been observed, highlighting a mainly globular shaped microstructure as expression of the attained semi-solid conditions during the processes. A critical analysis has been developed to evaluate the real potential and to present some criticism of the process.

Semi-solid squeeze casting process of a ZL109 alloy

Rare Metals ◽  
2008 ◽  
Vol 27 (3) ◽  
pp. 329-334 ◽  
Author(s):  
Y ZHAI ◽  
C LIU ◽  
Z HAN ◽  
K WANG
Keyword(s):  
Squeeze Casting ◽  
Casting Process ◽  
Semi Solid ◽  
Squeeze Casting Process

Finite Element Analyses and Model of Squeeze Casting Process for Producing Magnesium Wheels

2012 ◽  
Vol 557-559 ◽  
pp. 2299-2302
Author(s):  
Chang Jiang Lin ◽  
Yin Jin ◽  
Hong Qing Tang
Keyword(s):  
Finite Element ◽  
Squeeze Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Die Design ◽  
Finite Element Analyses ◽  
Alloy Wheel ◽  
Filling And Solidification ◽  
Squeeze Casting Process

A finite element equation has been developed to simulate the squeeze casting process of a magnesium alloy wheel, a parametric model has been established to confirm the temperature field during filling and solidification process. The model can be used to investigate the effects of die design and process parameters (die temperature, pressure etc.) on the quality of castings.

Numerical Simulation of Semi-Solid Die Casting Process of Magnesium Alloy

2011 ◽  
Vol 474-476 ◽  
pp. 255-259 ◽  
Author(s):  
Ya Ping Hu ◽  
Yong Hu
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Flow Characteristics ◽  
Casting Process ◽  
Die Design ◽  
Filling Process ◽  
Die Filling ◽  
Gas Cavity ◽  
Die Casting Process ◽  
Semi Solid

Numerical simulation can be used to predict die filling, and hence to optimize the die design. In the study, the flow characteristics of liquid filling comparing with those of semi-solid filling were analyzed. The results indicated that the liquid filling turned out to be turbulent, while the semi-sold filling had laminar flow characteristics which could reduce the foundry defects such as gas cavity and oxidation mixture. The distribution of pressure reduced gradually in the filling direction during semi-solid filling process which would generate back pressure that was favorable for filling process.

Determination of Die Design Rules for Semi-Solid Die Casting Process and Its Experimental Investigation

2005 ◽  
Vol 475-479 ◽  
pp. 2533-2538 ◽  
Author(s):  
Chung Gil Kang ◽  
P.K. Seo ◽  
Byung Min Kim
Keyword(s):  
Heat Treatment ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Design Rule ◽  
Gating System ◽  
T6 Heat Treatment ◽  
Semi Solid ◽  
Line Design ◽  
Air Vent

Die design rule for semi-solid die casting (SSDC) with A356 electromagnetic stirring (EMS) aluminum alloy, was proposed. The die design rule included inspection of machine, part requirements, parting line determination, sleeve, plunger, gating system, overflow, air vent, ejector pin, and heating line design. The specification of gating system, overflow, air vent, plunger tip, and sleeve suitable for respective part were regulated. Two steps die system of lower-positioned gate and three steps die system of center-positioned gate were manufactured for 4 automobile suspension parts, based on the die design rule. For the sound filling pattern and solidification behavior, injection speeds of 4 parts were summarized to the interval (from V1 to V4). As a result of observing the microstructure of 4 parts after T6 heat treatment, primary Al-α phase was globularized and fine Si particles were distributed around the grain boundary. The mechanical properties of 4 parts with T6 heat treatment were investigated and showed ultimate tensile strength (UTS) of 330 MPa, yield strength (YS) of 250 MPa, and elongation of 7.5% as average.

Development of Semi-Solid Die Casting Process Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 850 ◽  
pp. 642-648 ◽  
Author(s):  
Song Chen ◽  
Da Quan Li ◽  
Fan Zhang ◽  
You Feng He ◽  
Qiang Zhu ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Die Casting ◽  
Structure Optimization ◽  
Casting Process ◽  
New Product ◽  
Product Structure ◽  
Die Design ◽  
Design Parameters ◽  
Die Casting Process ◽  
Semi Solid

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.

Effect of solid fraction on formability and mechanical properties in a vertical-type rheo squeeze-casting process

2011 ◽  
Vol 225 (2) ◽  
pp. 184-196
Author(s):  
S M Lee ◽  
C G Kang
Keyword(s):  
Solid Fraction ◽  
Squeeze Casting ◽  
Volume Fraction ◽  
Die Casting ◽  
Solid Volume Fraction ◽  
Casting Process ◽  
Spherical Particles ◽  
Forming Process ◽  
Dendritic Microstructure ◽  
Squeeze Casting Process

This paper demonstrates an electromagnetic stirring (EMS) process which strongly stirs the molten metal at the initial stage of solidification, in order to transform the dendritic microstructure into fine spherical particles close to a globule; the paper accordingly suggests that the vertical squeeze-casting process is suitable for forming rheological material into engineering parts. Thus, this study investigates the performance of the vertical rheological die-casting process for developing highly functional and lightweight engineering parts. The vertical squeeze-casting process was optimized to obtain a high-quality product by controlling the solid volume fraction through EMS, as well as the velocity of injection in the rheological forming process; subsequently, the formability of the product was estimated. As a result, the mechanical characteristics of the product fabricated for each condition could be examined. In this study, the channel type of product was selected because of its feasibility to be adapted to a vehicle component of rheological materials. It is suggested that when rheological materials formed by the EMS process, which controls the solid fraction of rheological material, are manufactured into engineering components by vertical die-casting, the fine microstructure of the product can be fabricated.

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