• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.10
• /
• pp.102-108
• /
• 1997

The technology of Semi-Solid Forging (SSF) has been actively developed to fabricate near-net- shape products using light and hardly formable materials. Generally, the SSF process is composed of slug heating, forming, compression holding and ejecting step. After forming step in SSF, the slug is compressed during a certain holding time in order to be completely filled in the die cavity and be accelerated in solidification rate. This paper presents the analysis of temperature, solid fraction and shrinkage at compression holding step for a cylindrical slug, then predicts the solidification time to obtain the final shaped part. Enthalpy-based finite element analysis is performed to solve the heat transfer problem considering phase change in solidification.

• Journal of Korea Foundry Society
• /
• v.37 no.5
• /
• pp.157-163
• /
• 2017

In the present study, the microstructural evolution and deformation behavior of AA 2014 aluminum alloys with different microstructures in a semi-solid state were investigated. For a given alloy, applied load and deformation time, the measured strain was higher at a higher temperature, indicative of a lower solid fraction. When a large proportion of the liquid was present as intragranular droplets, the alloy would not as easily deform because the effective liquid fraction between the solid grains had decreased. Greater deformation was achieved with higher grain boundary misorientations due to the enhanced wetting of the grain boundaries with liquid. A semi-empirical constitutive model is proposed for semi-solid deformation under the conditions in the present study. The mechanism of semi-solid deformation incorporates the initial flow of the liquid in the early stages of deformation, followed by a more gradual increase in the strain due to deformation by grain sliding accompanied by self-diffusion in the solid grains.

• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.8
• /
• pp.82-91
• /
• 1997

The major objective of this study is to establish analytical technique in order to analyze the behaviour of semi-solid material considering induction heating of the billet. Induction heating process is analyzed by using commerical finite element software. ANSYS. The finite element program, SFAC2D, for the simulation of deformation in semi-solid state is developed in the present study. The semi-solid behaviour is described by a viscoplastic model for the solid phase, and by the Darcy's law for the liquid flow. Simple compression and closed-die compression process considering induction heating are analyzed, and also it is found that the distribution of initial solid fraction of the billet has an important effect on deformation behaviour of semi-solid material. In order to verify the effectiveness of proposed analytical technique the simulation result is compared with experimental result.

• Transactions of Materials Processing
• /
• v.6 no.4
• /
• pp.319-328
• /
• 1997

A flow stress involving strain, solid fraction, and breakage ratio, and solid fraction updating algorithm were proposed to depict the deformation behavior of materials at the semi-solid state. In case of isothermally simple upsetting of Sn-15%Pb alloy at the semi-solid state, by comparing the results of finite element analysis with the existing experimental results, the reliability of both the developed flow stress and updating algorithm were investigated. It was found that the verified program can effectively be used in the rigid-viscoplastic finite element analysis of the semi-solid forging processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1997.06a
• /
• pp.135-147
• /
• 1997

The production of light metal parts using aluminum is mainly performed by die casting and squeeze casting, which directly fabricate the required shape from the liquid state. However, die casting is subject to defects such as shrinkage porosity and air trapped when molten metal enters the cavity, whilst squeeze casting also has defects due to turbulent flow in the die cavity. Both diecasting and sqeeze casting have inhomogeneous mechanical property in terms of dendritic structure during solidification. Active research has been carried out on semi-solid processing, rather than on conventional process methods such as die casting, which involve various problems. Therefore in this paper, to introduce the fundamental technology for d e design, in die casting and forging process with semi-solid materials, relationship between stress and strain of semi-solid materials, and for producing parts die design has been proposed as parameters of globulization of the microstructure and gate shape. The prevention of various defects to produce sound parts are also introduced.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1997.04a
• /
• pp.670-674
• /
• 1997

Semi-solid forging is a compound forging technology to deventional forging process. Among several steps of semi-solid forging process, the heating step of a billet prior to semi-solid forging step is necessarily required to obtain globular microstructure. For the forming operation to work properly, it is also important to heat the billet uniformly for the uniformity of solid-liquid distribution. To satisfy these requirements, induction heating has been generally used for a long time. This paper presents the method to find heating condition and the temperature distribution inside of a billet with a induction heating apparatus by comparing the computer simulation with experiment for aluminum alloys Al2024 and A356.

• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.8
• /
• pp.15-20
• /
• 1997

Semi-solid forging is a compound forging technology to develop conventional forging process. Among several steps of semi-solid forging process, the heating step of a billet prior to semi-solid forging step is necessarily required to obtain globular microstructure. For the forming operation to work properly, it is also important to heat the billet uniformly for the uniformity of solid-liquid distribution. To satisfy these requirements, induction heating has been generally used for a long time. This paper presents the method to find heating condition and the temperature distribution inside a billet with a induction heating apparatus by comparing the computer simulation with experiment for aluminium alloys A12024 and A356.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1996.11a
• /
• pp.110-114
• /
• 1996

The objective of this study is to consider the induction heating process and to develop the finite element program to analyze the behaviour of semi-solid materials. The semi-solid material is assumed to be composed of solid region as rigid visco-plastic model and liquid region following Darcy's law. Induction heating process is analyzed using finite element software, ANSYS, and also the behaviour of a semi-solid material considering induction heating is analyzed using developed finite element program.

• Transactions of Materials Processing
• /
• v.18 no.1
• /
• pp.26-38
• /
• 2009

It was reported that the semi-solid forming process has many advantages over the conventional forming process, such as a long die life, good mechanical properties and energy savings. It is very important, however, to control liquid segregation to gain mechanical property improvement of materials. During forming process, rheology material has complex characteristics, thixotropic behavior. Also, difference of velocity between solid and liquid in the semi-solid state material makes a liquid segregation and specific stress variation. Therefore, it is difficult for a numerical simulation of the rheology process to be performed. General plastic or fluid dynamic analysis is not suitable for the behavior of rheology material. The behavior and stress of solid particle in the rheology material during forging process is affected by viscosity, temperature and solid fraction. In this study, compression experiments of aluminum alloy were performed under each other tool shape which is rectangle shape(square array), rectangle shape(hexagonal array), and free shape tool. In addition, the dynamics behavior compare with Okano equation to power law model which is viscosity equation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1997.03a
• /
• pp.159-164
• /
• 1997

The optimal conditions were investigated in order to manufacture the light automotive body parts using the semi-solid forging process by the finite element nalysis. Considering about macro-segregation cause to difference of relative velocity between solid phase and liquid phase, solidificational phenomenon cause to heat transfer from die and export of the latent heat, so solid fraction updating algorithm can be proposed. The rigid thermo-viscoplastic finite element analysis was carried out according to die temperature with proposed algorithm, so availability of forming part were understood. The finite element program can be used to the analysis of semi solid forging process.