Computer-Aided Designs of Die and Thermal Control for Fabrication of A356 Wheels

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  • Huang Xiu Song
    National Center of Novel Materials for International Research, Tsinghua University Department of Mechanical Engineering, Tsinghua University
  • Lv Zhi Gang
    National Center of Novel Materials for International Research, Tsinghua University Department of Mechanical Engineering, Tsinghua University
  • He Liang Ju
    National Center of Novel Materials for International Research, Tsinghua University
  • Mi Guang Bao
    National Center of Novel Materials for International Research, Tsinghua University
  • Li Pei Jie
    National Center of Novel Materials for International Research, Tsinghua University Department of Mechanical Engineering, Tsinghua University

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Horizontal squeeze casting (HSC) is a potential method for casting aluminum alloy wheels. In this study, the process for HSC of an A356 wheel was modeled and simulated. After analysis of the velocity and temperature fields during the casting process, the designs of the die and thermal control were modified and the effects of the design modifications on two key characteristics of HSC were studied: slow filling and squeeze feeding. An increase in the gate size and the use of exhaust slots reduced the tendency for gas to become entrapped. Furthermore, the increase in the gate size and application of thermal control allowed squeeze feeding for the wheel hub to be achieved successfully. Finally, experiments were performed to verify the results of simulation.

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