Abstract
The mold filling of semi-solid slurry involves intricate theory and physical phenomenon. The influence of inner gate shape and filling speed on free surface and liquid-solid distribution is investigated by adopting finite element numerical simulation. The effect of viscosity is considered in the modelling. The results show that the inner gate shape affects the free surface. The filling speed of 3 m/s is favorable for the uniform distribution of solid-liquid phases. It has important guiding significance for the optimization of semi-solid forming process and molding design.
Highlights
Semi-solid formed castings have the advantages of compact microstructure and excellent mechanical properties, which have been widely applied in automobile, aircraft, electronics and other industries[1,2,3]
If the mold design and the parameters options of filling process are unreasonable during semi-solid die casting, it would lead to defects, such as insufficient pouring, cold shut and shrinkage porosity
From the view of numerical simulation of forming process, a suitable rheological model of semi-solid slurry being established will directly affect the accuracy of simulation results
Summary
Semi-solid formed castings have the advantages of compact microstructure and excellent mechanical properties, which have been widely applied in automobile, aircraft, electronics and other industries[1,2,3]. The aluminum alloy has been widely discussed in many references for semi-solid forming[5,6]. The semi-solid mold filling of aluminum alloy is a very complex process, which involves fluid viscosity, heat transfer, computer graphics, calculation method, mathematical theory of partial differential equation and casting process theory[7]. From the view of numerical simulation of forming process, a suitable rheological model of semi-solid slurry being established will directly affect the accuracy of simulation results. This paper makes a full consideration with the viscosity changes of semi-solid slurry. The mold filling process of semi-solid slurry is simulated and analyzed by utilizing finite element numerical simulation
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