Development of the Simulated Die Casting Process by using Rapid Prototyping

쾌속 조형 공정을 이용한 다이캐스팅 제품의 시작 공정 개발

The simulated die-casting process in which the traditional plaster casting process is combined with Rapid Prototyping technology is being used to produce Al, Mg, and Zn die-casting prototypes. Unlike in the die-casting process, molten metal in the conventional plaster casting process is fed via a gravity pour into a mold and the mold does not cool as quickly as a die-casting mold. The plaster castings have much larger and grosser grain structure as compared as the die-castings and the thin walls of the plaster mold cavity may not be completely fillet Because of lower mechanical properties induced by the large grain structure and incomplete Idling, the conventional plaster casting process is not suitable for the trial die-casting Process. In this work, an enhanced trial die-casting process has been developed in which molten metal in the plaster mold cavity is vibrated and pressurized simultaneously. Patterns for the casting are made by Rapid Prototyping technologies and then plaster molds, which have runner system, are made using these patterns. Imparted pressurized vibration to molten metal has made grain structure of castings much finer and improved fluidity of the molten metal enough to obtain complete filling at thin walls which can not be filled in the conventional plaster casting process.