Abstract
The present article investigates the application of Taguchi’s experimental design and emphasizes about the application of DEFORM 3D simulation to predict the material flow in the semi-solid stage and to optimize the thixoforging parameters of semi-solid A356 alloy. From the Taguchi analysis, the optimum level of thixoforging process parameters to obtain maximum hardness of semi-solid processed components of A356 aluminum alloy were found to be at a thixoforging temperature of 580°C, a solid fraction of 0.5; deformation of 40% and die temperature of 200° C. Further, from the DEFORM simulation analysis similar optimal thixoforging process factors were also obtained as: deformation of 40% at a forging temperature of 580°C which corresponds to a solid fraction (fs = 0.5). Thus, the DEFORM 3D results showed how effective is the computer simulation in reducing the costly trial and errors and saving time.
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