Numerical integration design process to development of suspension parts by semi-solid die casting process

In recent years in the automobile industry, it has been necessary to reduce the weight of automobile parts. To solve this problem, lower arm parts have been fabricated with the aluminum alloy metal by semi-solid die casting as substitutes for steel arm parts. Aluminum alloy parts can reduce the weight of automobiles, but the mechanical properties of aluminum alloy parts are inferior to those of steel parts. In order to substitute aluminum alloys parts for steel arm parts, simulations of strength and fatigue have to be performed, before changing to new model designs. The die design for the semi-solid die casting of the arm part has to be considered according to defects from air porosities, impurities and filling errors. In this study, the filling and solidification processes were simulated in order to propose the optimal die design.