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

Abstract

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.

Current Progress in Rheoforming of Wrought Aluminum Alloys: A Review

“…With a continuous deep development of the artificial intelligence application technology, the highly integrated design and intelligent control of the rheoforming system is the shape of things to come. Special dies and moulds for rheoforming have been designed to enhance the mechanical properties while reducing the cost [140][141][142][143]. Moreover, even though the rheoforming of wrought Al alloy can offer considerable cost saving, high performance, and complex struture of parts, it is a quite long process to redesign a new part for rheofoming to replace the original product while meeting the acutual needs of industry, as displayed in Figure 12.…”

“…while reducing the cost [140][141][142][143]. Moreover, even though the rheoforming of wrought Al alloy can offer considerable cost saving, high performance, and complex struture of parts, it is a quite long process to redesign a new part for rheofoming to replace the original product while meeting the acutual needs of industry, as displayed in Figure 12.…”