Design and optimisation of the die tooling for liquid forging process

Abstract

This project aims to optimise the liquid forging die design to further exploit its advantages such as near-net-shape production, high aspect ratio, good mechanical properties. In this project, a die tooling was designed for a hard disc separator part to achieve single flow melt filling and mix secondary particles uniformly to minimises the casting defects from metal flow and to enhance mechanical properties. Different design alternatives were tested by computer simulations and were analysed systematically. The best design was chosen according to flow behaviours and particle mixing results and then it was further modified and improved. The finalised design consists of a triple 40° twist die tunnel and it was tested in physical experiments. The finalised design was able to achieve single flow melt filling, minor vortex forming and relatively uniform particles distribution.