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TECHNICAL PAPERS

An Experimental Investigation on Semi-Solid Forming of Micro/Meso-Scale Features

[+] Author and Article Information
Gap-Yong Kim

Department of Mechanical Engineering, University of Michigan, 2350 Hayward Street, Ann Arbor, MI 48109gykim@umich.edu

Jun Ni

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

Rhett Mayor

Department of Mechanical Engineering,  Georgia Institute of Technology, 813 Ferst Drive, N.W., Atlanta, GA 30332

Heesool Kim

Department of Mechanical Engineering, Yeungnam University, Gyongsan 712-749, South Korea

J. Manuf. Sci. Eng 129(2), 246-251 (Oct 16, 2006) (6 pages) doi:10.1115/1.2515402 History: Received May 26, 2005; Revised October 16, 2006

The potentials of semi-solid forming technology have generated much interest regarding its application in micromanufacturing. This study investigates the feasibility of using semi-solid forming technology to produce parts with micro/meso features. An experimental setup has been developed to study the effects of die/punch temperature, initial solid fraction, punch speed, and workpiece shape on the semi-solid forming process. A part has been produced for a microreactor application and has been analyzed with an optical measurement system for feature formation. The results indicated complex interaction among the process parameters and the material flow, which affected the final pin formation. The punch temperature and velocity had a significant effect on the overall die filling. The initial workpiece shape and solidification of the semi-solid material during forming influenced the micro/meso-feature formation sequence, affecting the final pin formation. Furthermore, grain deformation and distribution of the formed parts were investigated. The grains became larger due to induction heating and the forming process. Severely distorted grains were observed at the corner regions of the pins and the punch-workpiece interface.

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Copyright © 2007 by American Society of Mechanical Engineers
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Figures

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Figure 1

Layout of experimental setup

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Figure 2

Types of induction coils used for various workpiece shapes

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Figure 3

Temperature control of (a) the punch and (b) the die

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Figure 4

Schematic diagram of the die/punch operation and the punch design

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Figure 5

Dendritic and globular structure of Al–7%Si alloy

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Figure 6

Solid fraction versus temperature graph for Al–7%Si (20)

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Figure 7

Effect of punch temperature on die filling and applied force

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Figure 8

Effect of initial workpiece shape

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Figure 9

Measured part and features by laser inspection system

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Figure 10

Diagonal pin plots and pin volume distribution

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Figure 11

Row by row pin plots and pin volume distribution

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Figure 12

Measured pin shape and diagonal cross-sectional plot of a pin

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Figure 13

Grain shape and distribution of the formed part

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