Three-dimensional injection molding simulation of AZ91D semi-solid magnesium alloy

Magnesium alloys are increasingly used in automotive, aeronautic and electronic applications to produce high performance, light weight parts. In the thixomolding process a semi-solid slurry is injected into a mold at controlled temperature such that the melt has specific flow behavior. This allows t...

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Bibliographic Details
Published inInternational journal of material forming Vol. 1; no. 1; pp. 3 - 12
Main Authors Ilinca, Florin, Hétu, Jean-François, Moisan, Jean-François, Ajersch, Frank
Format Journal Article
LanguageEnglish
Published Paris Springer-Verlag 2008
Subjects
CAE) and Design
Computational Intelligence
Computer-Aided Engineering (CAD
Engineering
Machines
Manufacturing
Materials Science
Mechanical Engineering
Original Research
Processes
Finite elements
Semi-solid metal
Mold filling
3D Modeling
Shear thinning
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Summary:Magnesium alloys are increasingly used in automotive, aeronautic and electronic applications to produce high performance, light weight parts. In the thixomolding process a semi-solid slurry is injected into a mold at controlled temperature such that the melt has specific flow behavior. This allows the fabrication of near net shape components with controlled microstructure and good mechanical properties. The numerical modeling of such applications present unusual challenges for both the physical modelling and the solution algorithm. This paper presents a 3D numerical solution algorithm for the simulation of the injection molding of semi-solid AZ91 magnesium alloys. The methodology deals with the shear thinning, temperature dependent viscosity behavior and is able to accurately solve the high velocity flows encountered during semi-solid magnesium molding. A segregated algorithm is used to solve the Navier–Stokes, energy and front tracking equations. The position of the flow front in the mold cavity is computed using a level set approach. Equations are integrated in time using an implicit Euler scheme and solved by stabilized finite element methods. The approach is applied to the injection of a tensile bar and the results compared with experimental data. The methodology presents the robustness and cost effectiveness needed to tackle complex industrial applications.
ISSN:1960-6206
1960-6214
DOI:10.1007/s12289-008-0005-4