Analysis of forming of aluminium and magnesium alloys in semi-solid state by advanced computer modelling

Krzysztof Sołek¹ , Andrzej Białobrzeski², Tomasz Stuczyński³, Zbigniew Mitura¹

¹Akademia Górniczo-Hutnicza, al. Mickiewicza 30, 30-059, Kraków, Polska.
²lnstytut Odlewnictwa, Zakopiańska 73, 30-418 Kraków, Polska.
³Instytut Metali Nieżelaznych, Oddział Metali Lekkich, Piłsudskiego 19, 32-050 Skawina, Polska.

DOI:

https://doi.org/10.7494/cmms.2003.3.0042

Abstract:

“Metal forming in semi-solid state currently attracts a lot of research effort since only few manufacture steps lead to satisfactory mechanical properties even for complicated shapes. This paper presents recent authors? results for thixocasting. First, a whole technological process is described. Next, numerical modelling of pressure casting die filling (tixocasting process) is described. New constitutive equation parameters are obtained by means of inverse analysis and applied within package FORGE3. The main results are given for Al-Si alloy; however; some preliminary discussion for Mg-Al investigation is also provided. The presented results would seem Io prove that reliable numerical simulation of advanced technological processes is possible.

Cite as:

Sołek, K., Białobrzeski, A., Stuczyński, T., Mitura, Z. (2003). Analysis of forming of aluminium and magnesium alloys in semi-solid state by advanced computer modelling. Computer Methods in Materials Science, 3(3-4), 126 – 137. https://doi.org/10.7494/cmms.2003.3.0042

Article (PDF):

Keywords:

References:

Atkinson, H.V. (2002). Thixoforming of otherwise wrought aluminium alloys: thermodynamic prediction of amenable compositions. Mat. Konf. 5th Int. Conf. on Material Forming ESAFORM, ed., Pietrzyk, M., Mitura, Z., Kaczmar, J., Kraków, 655-658.

Bellet, M., Mpong, S.M. (2001). Determination of the constitutive equation parameters of’a thixotropic Al alloy and FEM modelling of the thixoforming process. Mat Konf. NUMIFORM ‘01, ed., Mori, K., Lisse, 1087-1092.

Chenot, J.-L., Bellet, M. (1992). The Viscoplastic Approach for the Finite-Element Modelling of Metal-Forming Processes. Praca Zbiorowa Numerical Modelling of Material Deformation Processes, ed., Hartley, P., Pillinger, I., Sturgess, C., London, 179-224.

Chino, Y., Kobata, M., Iwasaki, H., Mabuchi, M. (2003). An investigation of compressive deformation behaviour for AZ91 Mg alloy containing a small volume of liquid. Acta Materialia, 51, 3309-3318.

Feather, F. (2000). Canada’s best careers guide 2000. Warwick Publishing, Toronto.

Hepp, E., Neves, S., Egry, I. (2000). High precision measurement of thermophysical properties for liquid metals – requirements for simulation of foundry processes. Mat Konf. Modeling of Casting, Welding and Advanced Solidification Processes IX, ed., Sahm, P. R., Hansen, P. N., Conley, J. G., 697-703.

Kang, C. G., Chung, Y. J. (2001). Comparison of single-phase and two-phase flow for numerical analysis of semi-solid forming process. Mat Konf. NUMIFORM ’01, ed., Mori, K., Toyohashi, 1079-1085.

Kopp, R., Lugscheider, E., Hornig, T., Kallwiet, J., Maes, M., Seidl. I. (2002). Forming experiments and die development for processing steels in the semi-solid range. Mat. Konf: 5th Int. Conf. on Material Forming ESAFORM, ed., Pietrzyk, M., Mitura, Z., Kaczmar, J., Krakow, 671-674.

Łapkowski, W., Pietrzyk, M., Sińczak, J. (1992). Behaviour of metal alloys during plastic deformation in partly liquid state. J. Mater. Proc. Techn., 34, 481-488.

Lapkowski, W., Pietrzyk, M. (1994). Some aspects of plastic deformation of metal alloys in partly liquid state. J. Mater: Proc. Techn., 45, 365-370.

Lapkowski, W. (1998). Some studies regarding thixoforming of metal alloys. J. Mater. Proc. Techn., 80-81, 463-468. Mori, K., ed., 2001, Mat Konf. NUMIFORM ’01, A.A. Balkema Publishers, Lisse.

Petera, J., Modigell, M., Hufschmidt, M. (2002). Comparison of twophase finite simulation with experiments on isothermal die filling of semi-solid tin-lead. Mat. Konf. Sth Int. Conf. on Material Forming ESAFORM, ed., Pietrzyk, M., Mitura, Z., Kaczmar, J., Krakow, 675-678.

Perzyk, M., Iwaszkiewicz, S., Kaczorowski, M., Jopkiewicz, A. (2000). Odlewnictwo. Wydawnictwa Naukowo-Techniczne, Warszawa. Pietrzyk, M., Mitura, Z., Kaczmar, J., ed., 2002, Mat. Konf. 5th Int. Conf. on Material Forming ESAFORM, Akapit, Krakow.

Reddy, J. N., Gartling, D. K. (2001). The Finite Element Method in Heat Transfer and Fluid Dynamics. CRC Press, London.

Sahm, P.R., Hansen, P.N., Conley, J.G., ed., 2000, Mat Konf. Modeling of Casting, Welding and Advanced Solidification Processes IX, Shaker Verlag GmbH, Aachen.

Szyndler, D., Pietrzyk, M. (2000). Inverse analysis applied to the evaluation of friction and rheological parameters in hot forming of steels. Mat. Konf. Metal Forming ’00, ed., Pietrzyk, M., Kusiak, J., Majta, J., Hartley, P., Pillinger, I., Krakow, 101- 106.

Szyndler, D., Pietrzyk, M., and Kuziak, R., 2001, Estimation of rheological and friction parameters in hot forming processes as inverse problem, Mat. Konf: ESAFORM ’01, ed., Habraken, A. M., Liege, 191-194.

Wagoner, R.H., Chenot, J.-L. (1997). Fundamentals of metal forming. John Wiley & Sons, Inc., New York.

Wagoner, R.H., Chenot, J.-L. (2001). Metal Forming Analysis. Cambridge University Press, Cambridge.