Finite element analysis of semi-solid die-casting technology of magnesium alloy hook based on anycasting

Abstract

According to the die-coasting forming principle, several ingates of different sizes and semi-solid die-casting technology parameters were designed in this paper. The solid modeling of the casting was created based on Pro/E software. The simulation of the filling process of semi-solid die-casting of Magnesium alloy hook used in the train was made by using the finite element analysis software AnyCasting. And the apparent viscosity test of semi-solid magnesium alloy AZ91D was done by using a self-designed coaxial double-barrel rheometer in order to investigate the changing laws of apparent viscosity under different shear temperatures and shear rates. The study results show that the apparent viscosity of Magnesium alloy AZ91D decreased obviously with the shear strength increasing at 42% of the solid-phase ratio, which is suitable for the semi-solid forming of Magnesium alloys. To avoid creating air holes, shrinkages and other defects in castings, the thickness of ingates should be appropriately increased to make the semi-solid metal slurry flow in the way of laminar flow much easily when filling the mold. The semi-solid magnesium alloy AZ91D has good rheological properties under the conditions of mixing temperature 570? and shear rate 88.85 s - 1. The quality of castings is ideal when switching the speed at the time of low injection speed 0.1 m/s, high injection speed 1 m/s and the filling rate up to 65%. © the authors.