Application of Computer Simulation in Developing Automotive Parts of Al Alloy by Using Semi-Solid Die Cast Process

Abstract

To aid the optimizing design of filling system, computer simulation technique is introduced to predict injection-forming process and to protect defects during trial manufacture of automotive parts by using semi-solid die cast process. By comparing formed appearance of parts in experiments and that in simulations, and observing the relationship between internal defects inspected by X-ray and flow field obtained in simulation, it is indicated that there are quite good agreements between simulation and experiment, right predictions for cast defects resulting from filling process can be made and improving direction is proposed. The realization of numerical visualization for filling process of high speed during semi-solid die cast process will play an important role in optimizing technology plan and process.Introduction Semi-solid die cast process with many features [1], [2] is a forming technology developed on the base of general molten metal die cast, and is gradually becoming maturity as near-net-shape processing of material. Comparing with traditional die cast, there are a lot of unsolved technology problems in Semi-solid die cast process. For example, because mature data are absent from the design of gating system, design experiences in die cast of molten metal are used. To optimize forming process, to aid the die design and to forecast cast defects, the introduction of computer simulation will play an important promoting role in enhancing technique level of semi-solid formation and product quality. As one of the steps in which automotive parts are systematically developed, using simulation technique during trial manufacture of Al alloy parts aims at optimizing forming technology and improving quality of product.

Effect of Heat Treatment on the Resistivity and Mechanical Property of Low-Pressure Semi-Solid Die Cast Aluminum Alloy Wheel

“…Aluminum alloy wheel, which has the features of safe, comfortable and energy-saving , can effectively reduce the car's weight [1]. A356 aluminum alloy has a good casting performance and a superior specific strength than steel.…”