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Studies on die filling of A356 Al alloy and development of a steering knuckle component using rheo pressure die casting system

Das, Prosenjit and Bhuniya, Bikash and Samanta, Sudip K. and Dutta, Pradip (2019) Studies on die filling of A356 Al alloy and development of a steering knuckle component using rheo pressure die casting system. In: JOURNAL OF MATERIALS PROCESSING TECHNOLOGY, 271 . pp. 293-311.

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Official URL: https://doi.org/ 10.1016/j.jmatprotec.2019.04.014

Abstract

In this study, a computational fluid dynamics (CFD) model is developed to investigate die filling of semi solid slurry as part of rheo pressure die casting (RPDC) system. The die filling cavity corresponds to that of an automobile steering knuckle, and the slurry is made of A356 aluminium alloy. The rheological model used in the CFD simulation is determined experimentally. The results obtained from present numerical model includes flow field of the slurry within the die cavity, viscosity evolution, solid fraction distribution, temperature and pressure distribution during solidification within cavity during die filling stage. The main objective of the study is to determine the gating arrangement, pouring temperature, and injection conditions for desirable microstructure and mechanical properties of the developed component. To study the effect of injection conditions on die filling capability of the said alloy slurry, five injection profiles are studied, with a variation in final injection velocity between 2-3.2 m/s. In order to corroborate the findings of the present study, microstructural morphology and structure-property correlation have been studied, primarily in the form of optical microscopy and macro hardness measurements, by obtaining samples from different locations of the solidified component.

Item Type: Journal Article
Additional Information: copright of this article belongs to ELSEVIER SCIENCE SA
Keywords: Steering knuckle; Semi solid; RPDC; A356 alloy; Die filling
Department/Centre: Division of Mechanical Sciences > Mechanical Engineering
Depositing User: Id for Latest eprints
Date Deposited: 01 Jul 2019 08:28
Last Modified: 01 Jul 2019 08:28
URI: http://eprints.iisc.ac.in/id/eprint/63102

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