Design And Analysis Of Thixoforming Alternator Housing Using Advance Casting Simulation Software

Mohamad Pzil, Nor Faezah (2017) Design And Analysis Of Thixoforming Alternator Housing Using Advance Casting Simulation Software. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

Text (24 Pages) Design And Analysis Of Thixoforming Alternator Housing Using Advance Casting Simulation Software.pdf - Submitted Version Restricted to Registered users only until 31 August 2023. Download (816kB)

Abstract

Thixoforming is a promising metal forming process to produce near net shape components with high casting quality.Thixoforming of metallic alloy utilizes the thixotropic behavior of the material with non-dendritic microstructure in the semi-solid state.In fact,semi-solid slurry has significantly higher viscosity than molten metal.This characteristic of fluidity makes mold design such as gating system is different for both conventional metal casting and thixoforming.Based on thixoforming die design principle,a mold for thixoforming alternator housing were designed in this paper.3D CAD modeling of the part is created by using SolidWork and the casting process is simulated by using advanced casting simulation software,AnyCasting.The scope of this project is to design a thixoforming mold and analyze the filling behavior of semi-solid AZ91D.The simulation had been done by varying the injection speed and the melts temperature. The viscosity model used in this project is Power Law and Bingham Viscosity model.From the simulation,it shown that injection speed and temperature do affect the filling and solidification time.When injection speed is lower,range from 0.1m/s to 0.5m/s,the filling time is slower, approximately 0.5501s to 2.75s.But,the lower injection speed give out better die filling with laminar and stable filling.In contrast,when the injection speed is high which is 1.0m/s,the filling time is faster,but it caused unstable filling and might end up with air entrapment. Therefore,the simulation also shown defects that might occur such air entrapment,porosity and turbulence flow. Using AnyCasting software,mechanical and microstructure prediction had been analyzed.Mechanical properties analyzed are Vickers Hardness with result obtained is 66.88 Hv,Tensile Strength and Percentages of Elongation with result of 125.3MPa and 3.89% espectively.

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