• Title/Summary/Keyword: thixoforming

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The Effects of Forming Defects on the Mechanical Properties of Thixoformed Aluminum Parts for Automobile (반응고 성형된 자동차용 알루미늄 합금 부품의 기계적 강도 특성에 미치는 성형 결함의 영향)

  • Kim, C.H.;Choi, B.H.;Lee, S.Y.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2007.10a
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    • pp.293-295
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    • 2007
  • The thixoforming process become important for forming automobile parts. But, the thixoforming process cannot still prevent to forming defects such as pores and shrinkage which reduce mechanical properties of automobile parts. Therefore, it is necessary to analyze the correlation between forming defects and mechanical properties. However, it is difficult to get data about relations between mechanical properties and forming defects in thixoformed aluminum alloy parts. In this study, three parts of aluminum thixoformed knuckle have been analyzed using tensile test and computer tomography(CT scan). Experimental results showed that the elongation properties of thixoformed aluminum parts were significantly dependent on size and number of forming defects.

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Reheating of Semi-Solid Material Using Multi-Capacity Induction Heating System (다출력 유도 가열 시스템에 의한 반용융 소재의 재가열)

  • 정홍규
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1999.03b
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    • pp.199-202
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    • 1999
  • Many processing times for fabricating complex shaped parts by near net shape process such as thixoforming or semi-solid forming, are required due to the time for die design, induction heating and forming process. Therefore, for the thixoforming process, multi-capacity induction heating process is very important due to the reduction of the processing time and cost. It is indispensable to adopt a power-time heating pattern which manages to conciliate complete eutectic melting at the core with limited overheating at the periphery. The total reheating time is thus dependent on billet diameter; in inches$(pm20%)$. Typically, high frequency is used for the rapid reheating of the billet to the eutectic temperature range and low frequency for the remelting of the desired fraction of liquid and for the radial homogeneization of the liquid fraction. So in this study, the multi-capacity induction heating conditions of ALTHIX 86s alloy to reduce the processing time and cost would be proposed. The suitability of multi-capacity induction heating conditions would be verified through the comparison to Garat's data.

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Research Trends of Rheology Forming and Their Solutions to Mass Production (금속레오로지 소재성형의 연구동향 및 대량생산을 위한 해결 방안)

  • 강충길
    • Transactions of Materials Processing
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    • v.11 no.2
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    • pp.123-131
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    • 2002
  • The rheology process is net shape manufaturing technology to high of automobile part and improve the mechanical properties. For the rheology forming process, Phase and globular microstructure are very important. The equipments to make a rheology alloys with slurry statement have been introduced. Therefore, the Problems to Produce a rheology alloyas with continuous process had also been investigated to make Production in industries. The validity of the introduced rheology Process is investigated by comparing the reported thixoforming results. Therefore, the many advantage of rheology process to be reduced the reheating Process and billet fabrication method has been expressed in terms of mass production, in the future.

Reheating Process of Extrusion Billet with Large Dimension (대형 압출 빌렛트의 재가열 공정)

  • 배정운;서판기;강충길
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2003.10a
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    • pp.261-264
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    • 2003
  • Semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Many advantages are associated with this forming process at the condition that the forming operation is performed under appropriate conditions. The thixoforming process, which needs a suspension of a globular, non-dendritic solid phase in the liquid phase, is characterized by three major steps. The first step is casting of billets with a microstructure suited for thixoforming. The second step is reheating of slugs cut from these billets. The third step is injection of the semi-solid slugs into a die. In this paper, the horizontal reheating machine to obtain the optimal conditions suitable for semiu-solid die casting process was used and applied to extrusion material. It is estimated the possibility of application on semi-solid die casting with extrusion material through various results.

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Horizontal Reheating of Aluminium Alloys for Thixoforming (Thixoforming을 위한 연주 Billet의 수평형 재가열)

  • Park S. M.;Kang C. G.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2001.05a
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    • pp.120-123
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    • 2001
  • The semi-solid casting will have a higher internal integrity, mechanical properties and dimensional accuracy than the conventional castings. This process can reduce the manufacturing costs and finished weight for critical components. The semi-solid casting are capable of greater dimensional repeatbility, this supplies considerable savings when extensive machining, salvage and scrap are key variables in the current automotive product. One of the most important factor regarding the semi-solid die casting process are the reheating method of the raw materials to the semi-solid state. Therefore, in this present work, the horizontal type induction heating system to obtain the optimal reheating conditions suitable for semi-solid die casting process was designed and manufactured. And the microstructure of reheated materials was investigated.

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The Effects of Fabrication Conditions on Forging Limitation and Mechanical Property in Semi-Solid Forming Process (반용융 단조공정에 있어서 제조 조건이 성형성과 기계적 성질에 미치는 영향)

  • 정경득;강충길
    • Transactions of Materials Processing
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    • v.10 no.3
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    • pp.214-222
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    • 2001
  • The homogeneous distribution of solid region without liquid segregation is important in terms of high quality component during thixoforming process. In closed die semi-solid forging process, liquid segregation is strongly affected by injection velocity than solid fraction because the material has to travel relatively long distance to fill the cavity through a narrow gate. The designed die by computer simulation data was used to thixoforging process. The thixoforming velocity to prediction the liquid segregation had been determined with strain rate associated with multistage velocity control during compression test of semi-solid material. The optimal forging velocity and die temperature were investigated to produce the near-net-shape compressor component. The mechanical properties of thixoformed component were tested with various die and material temperatures before and after heat treatment.

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Die Design of Semi-Solid Forging by Computer Simulation and their Experimental Investigation (Computer Simulation에 의한 Semi-Solid 단조금형의 설계 및 실험적 검정)

  • Seo P. K.;Lee D. H.;Kang C. G.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2000.10a
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    • pp.185-190
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    • 2000
  • Die design by computer simulation has some advantages compared with the conventional method which has performed by designer's experiences and trials and errors. The die filling and solidification process of thixoforming process were simulated by MAGMAsoft/thixo module. First of all, thixoforming die design was applied to previously geometry shape. The value of pressure distribution shows high and uniform as the gate diameter is 18mm. Designed gating system considering the deformation of die and product was suggested by the filling simulation. Gate velocity(7.25m/s) of designed gating system shows that propriety to semi-solid metal working process and CAE results were in good agreement with experimental results.

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Optimization of Induction Coil Design for Reheating in Thixoforming Process (Thixoforming을 위한 재가열용 유도코일 설계의 최적화)

  • 김남석
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 1999.03b
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    • pp.165-168
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    • 1999
  • The coil design of induction heating systems and their optimization are of paramount importance for semi-solid processing(SSP) The authors of this paper present the coil design and optimization of a 60 Hz induction heating system for ALTHIX 86S (Al-6%_Si-3%Cu-0.3%Mg) alloy. An objective function on the basis of the optimization process for the coil design is proposed by introducing an optimization technique. Finally the results of the optimal coil design are also applied to the induction heating process to obtain a fine globular microstructure. The proposed new objective function based on the computational techniques would contribute to obtaining the thixoformed components with good mechanical properties and reducing lead time.

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Measurements of Micro-Defects in the Aluminum Thixoformed Part using Computed Tomography(CT) Technology (CT를 이용한 알루미늄 반응고 성형품의 미세 결함 측정)

  • Lee, S.Y.;Kim, C.H.
    • Transactions of Materials Processing
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    • v.18 no.5
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    • pp.422-427
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    • 2009
  • Computed tomography(CT) has been applied to measure micro-defects in the aluminum knuckle parts manufactured by the thixoforming process. 6061 aluminum alloys were used to form knuckle samples in the semi-solid temperature after the SIMA processing of billets. Tensile specimens were cut from the different locations in a thixoformed knuckle. The size and the distribution of forming defects in tensile specimens were analyzed using CT scanning and image analysis technology before tensile tests. It has been qualitatively shown that the stress-strain curves were significantly affected by the size and the distribution of forming defects although the defect sizes lie in the range of micro-meters.