Simulation on Flexible Thixo-Extrusion of Variable Cross-Section Part Based on DEFORM-3D Software

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.

• Periodical: Solid State Phenomena (Volumes 217-218)
• Pages: 201-207
• DOI: https://doi.org/10.4028/www.scientific.net/SSP.217-218.201
• Online since: September 2014
• Authors: Chun Fang Wang, Kai Kun Wang*, Zhe Luo
• Keywords: Flexible Thixo-Extrusion, Sliding Bricks, True Stress-Strain Curve, Variable Cross-Section Parts

References

[1] Wang K K . Thixo-forging and simulation of complex parts of aluminum alloy AlSi7Mg [J]. International Journal of Minerals, Metallurgy and Materials, 2010, 17(1): 53-57.

DOI: 10.1007/s12613-010-0109-y

[2] Kopp R, J. Schulz. Flexible Sheet Forming Technology by Double-sided Simultaneous Shot Peen Forming[J]. CIRP Annals-Manufacturing Technology, 2002: 195-198.

DOI: 10.1016/s0007-8506(07)61498-x

[3] WANG Kai-kun, C.N. Patent CN101015857. (2007).

[4] Wang K K, Sun JL, Kang YL, et al. Investigation on inductive heating of A356 alloy for thixo-forming [J]. International Journal of Minerals, Metallurgy and Materials, 2009, 16(3): 309-313.

DOI: 10.1016/s1674-4799(09)60055-8

[5] Urban M, Krahn M, Kopp R, et al. Numerical research and optimisation of high pressure sheet metal forming of tailor rolled blanks [J]. Journal of Matetials Processing Technology, 2006：360-363.

DOI: 10.1016/j.jmatprotec.2006.03.195

[6] Tang X L, Shang S Z, Zhao F Q, et al. Research on the constitutive equation of 6061 aluminum alloys in the hot compressive deformation [J], Journal of plasticity engineering, 2011, 18(1): 110-113.

[7] Lv X L, Wang K K, Zhou L. Investigation on flexible thixo-extrusion of complex part [J]. Solid State Phenomena Vol. 2012: 192-193.

DOI: 10.4028/www.scientific.net/ssp.192-193.299