Sand casting and die casting processes have been used widely for complex automotive products such as knuckle, arm, etc.Usually, a part fabricated by casting has limited strength due to manufacturing defects such as the dendrite structure, segregation and porosities.As an attempt to offer a solution to these problems, forging has been used as an alternative process.However, the forging process provides limited formability for complex shape products.Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes.In order to produce semi-solid materials of the desired microstructure, a stirring process is applied during solidification of molten metal.The results of an A356 aluminum alloy sample, which are obtained by experiment and by simulation using DEFORM 3D, are present.
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