Abstract
Flexible thixo-extrusion, as an innovative near-net-shape forming method, has huge advantages in processing the components with complex geometry. However, it should keep in mind that conventional liquid casting still represents the dominant mean of aluminum alloys production. One of the obstacles the thixo-extrusion has to overcome is lack of proof that can live up to the claim that thixo-extruded components have better mechanical properties. The main aim of this paper is to simulate the flexible thixo-extrusion process of aluminum alloy A356 and investigate the control method of materials flow front. An isothermal compression test of aluminum alloy A356 is first conducted to obtain the true stress-strain curves at different temperatures and strain rates. A constitutive equation describing the relationship of stress, strain, strain rate and temperature is fitted by Origin and then imported to the DEFORM-3D simulation software. The results show that the quality of final component is enormously influenced by the radius of the arcs and the flexible thixo-extruded components has less defects compared with the conventional extruded ones.
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