Optimization of Thixoforging process parameters of A356 alloy using Taguchi's experimental design and DEFORM Simulation

The present article investigates the application of Taguchi's experimental design and emphasizes about the application of DEFORM 3D simulation to predict the material flow in the semi-solid stage and to optimize the thixoforging parameters of semi-solid A356 alloy. From the Taguchi analysis, the optimum level of thixoforging process parameters to obtain maximum hardness of semi-solid processed components of A356 aluminum alloy were found to be at a thixoforging temperature of 580 degrees C, a solid fraction of 0.5; deformation of 40% and die temperature of 200 degrees C. Further, from the DEFORM simulation analysis similar optimal thixoforging process factors were also obtained as: deformation of 40% at a forging temperature of 580 degrees C which corresponds to a solid fraction (f(s) = 0.5). Thus, the DEFORM 3D results showed how effective is the computer simulation in reducing the costly trial and errors and saving time. (C) 2017 Elsevier Ltd. All rights reserved.