Die design by filling analysis of semi-solid injection forging process and their experimental investigation

Abstract Die design by computer simulation has some advantages compared to the conventional method that was performed by designer’s experience and trial and error. The die filling and solidification phenomenon in semi-solid injection forging process were simulated by MAGMAsoft/thixo module. Furthermore, the die design for semi-solid injection forging was performed with the two kinds of geometric shapes. The effect of designed gate dimension on filling phenomenon was estimated by filling simulation. The calculated results were compared with experimental data. The free surface phenomenon obtained by experiment has good agreement with computer simulation results. The solidification affect much as porosity and shrinkage for designed semi-solid forging die had been predicted by computer simulation. The designed die for semi-solid injection forging had been applied to the production of the frame part used in air conditions system.