Modeling of the Semi-Solid Material Behavior and Analysis of Micro-/Mesoscale Feature Forming

[+] Author and Article Information
Gap-Yong Kim, Jun Ni

Department of Mechanical Engineering, University of Michigan, 2350 Hayward St., Ann Arbor, MI 48109

Muammer Koç

NSF I/UCR Center on Precision Forming (CPF) and Department of Mechanical Engineering, Virginia Commonwealth University, 601 West Main St., Richmond, VA 23284

Rhet Mayor

 Powerix, LLC, Ann Arbor, MI

J. Manuf. Sci. Eng 129(2), 237-245 (Oct 21, 2006) (9 pages) doi:10.1115/1.2673300 History: Received May 26, 2005; Revised October 21, 2006

One of the major challenges in simulation of semi-solid forming is characterizing the complex behavior of a material that consists of both solid and liquid phases. In this study, a material model for an A356 alloy in a semi-solid state has been developed for high solid fractions (>0.6) and implemented into a finite element simulation tool to investigate the micro-/mesoscale feature formation during the forming process. Compared to previous stress models, which are limited to expressing the stress dependency on only the strain rate and the temperature (or the solid fraction), the proposed stress model adds the capability of describing the semi-solid material behavior in terms of strain and structural evolution. The proposed stress model was able to explain the strain-softening behavior of the semi-solid material. Furthermore, a simulation model that includes the yield function, the flow rule, and the stress model has been developed and utilized to investigate the effects of various process parameters, including analysis type (isothermal vs nonisothermal), punch velocity, initial solid fraction, and workpiece shape (“flat” versus “tall”) on the micro-/mesofeature formation process.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Typical stress-strain curves for semi-solid material: (a) A356 (9) and (b)Sn-15wt.%Pb(10)

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Figure 2

Effects of parameters a and b on stress-strain curves

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Figure 3

Effects of parameters c and m on stress-strain curves

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Figure 4

Experimental and fitted values of parameters A and B in Eq. 1(9)

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Figure 5

Validation of A356 material model at various solid fractions

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Figure 6

Validation of A356 material model at various strain rates

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Figure 7

Relationship between the temperature and solid fraction of A356 (30)

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Figure 8

Apparent specific heat data for A356 (31)

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Figure 9

Punch force-displacement curve for the von Mises and current yield condition

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Figure 10

Simulation model and experimental setup

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Figure 11

Comparison between experimental and simulation results

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Figure 12

Simulation model for mesoscale feature forming

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Figure 13

Simulation results for force-displacement curves (fs=0.70)

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Figure 14

Channel formation process and solidification status at different loads for flat and tall shape workpieces

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Figure 15

Simulation results for solid fractions of 0.70 and 0.85 (V=10mm∕s)

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Figure 16

Strain distribution at final load (fs=0.70)

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Figure 17

Equivalent stress distribution




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