The Numerical Simulation Of Rheo-diecasting Process Of Filling And Solidification Of Semisolid Aluminum Alloy

At present, aluminum alloy has become one of metal construction materials with themost widely application, because of its small density, light weight, high strength, excellentelectrical conductivity, thermal conductivity and corrosion resistance, and recoverableness.In the aerospace industry, machinery manufacturing, automotive, electrical, construction,shipping and so on, it was applied in large. However in die-cast production process, thecasting defects such as shrinkage porosity, gas hole and so on, and not heat-strengthenedfor die-cast aluminum alloy limits its application range. There are more compactmicrostructures, high mechanical properties, less machining, long die life, less gas forsemi-solid metal forming parts. Therefore, as the development of semi-solid alloy diecasting technology, it will give the hope to the resolution of this problem.This paper, the numerical simulation of aluminum thin sheet, standard sample formechanical property, shell-shaped parts and motorcycle engine side cover were made byProCAST software and basic theory of casting numerical simulation of mold filling andsolidification process. The simulation results give the reference for the semi-solidrheological theory of die-cast mould design and process design.The mold filling and solidification process of aluminum thin sheet with thickness of2mm,5mm,8mm were simulated. The mold filling process, eddying flow, filling time,solidification and cast defects were analyzed, and processing parameters were optimized.The effects of mold filling speed, pouring temperature, specific pressure and sheetthickness on mold filling and solidification process of aluminum thin sheet were simulated.The influence factors on the law of mold filling and solidification process were analyzed.Using the combination of theoretical and practical approach, the effects of fillingprocess parameters on the mold filling and solidification process of aluminum die-caststandard sample were simulated. The experimental verification of simulation results wasmade.The mold filling and solidification process of shell-shaped parts were simulated, anda detailed analysis of the simulation results was made. On basis of the simulation ofaluminum thin sheet and shell-shaped, by the simulation of mold filling and solidification process on the side covers of motorcycle engine parts, the optimization of pr ocessparameters on themwas obtained.