Numerical Analysis of the Tool Load during the Manufacturing of a Flange in a Semi-Solid State

This article is aimed to a numerical analysis of the tool load during a forming process. First, a numerical model has been developed to study the effects of die/punch temperature, initial solid fraction and punch speed on the semi-solid forming process. Moreover, realistic numerical modeling of flow behavior is important to investigate the mechanical and thermally induced stresses in the tool. The model consists of two parts: one for the solid material and the other for the semi-solid state. At temperatures below the solidus temperature the material is described by means of flow curves and above the solidus temperature the viscosity curves are used to model the flow behavior. The solid fraction of the melt is directly linked to the current temperature and is calculated by using Scheil equation. The model equations are implemented into the FEA software simufact.forming GP and used for the simulation of a characteristic thixoforming process. The aim of this work is to evaluate the thermal and mechanical loadings applied to the tools during the steel thixoforging process. This evaluation has been realized thanks to experimental trials and to simulations.