Effect of Plunger Speed and Solid Fraction on Automotive Component by Thixoforming Simulation

Thixoforming is a promising metal forming process to produce near net-shape components with high casting quality. Thixoforming of metallic alloy utilizes the thixotropic behaviour of the material with near globular or globular microstructure in the semi-solid condition. The solid content is between 50% to 70% before forming. In this paper, the effect of plunger speed and a solid fraction on an alternator housing was investigated by advance casting simulation software. The 3D CAD model of the alternator housing was created using SolidWorks software and AnyCasting software is utilized for the simulation of the thixoforming parameter and magnesium alloy (AZ91D) is the material used. The simulation had been done by varying the plunger speed, temperature (solid fraction) of the material, and both Power Law and Bingham Viscosity model are used in the simulation to identify the defect prediction at the end. The simulation result shows that laminar filling in semi-solid slurry able to achieved by controlling the plunger speed and temperature. Slower speed and lower melt temperatures are preferable in thixoforming. Therefore, a solid fraction of the material, plunger speed, and solidification rate do influence the filling behaviour of the casting of semi-solid metal.