Journal of Korean Society of Industrial and Systems Engineering (산업경영시스템학회지)

Society of Korea Industrial and System Engineering (한국산업경영시스템학회)
권호 표지
DOI QR코드

DOI QR Code

Casting Layout Design Using Flow & Solidification Analysis-Automotive Part(Oil Pan_BJ3E)

유동 및 응고해석을 이용한 주조방안설계-자동차용 부품(오일팬_BJ3E)

  • Kwon, Hong-Kyu (Dept. of Industrial and Management Engineering, Namseoul University)
  • 권홍규 (남서울대학교 산업경영공학과)
  • Received : 2018.12.18
  • Accepted : 2019.01.22
  • Published : 2019.03.31
Download PDF
⟨ Previous Next ⟩

Abstract

In the modern industrial period, the introduction of mass production was most important progress in civilization. Die-casting process is one of main methods for mass production in the modern industry. The aluminum die-casting in the mold filling process is very complicated where flow momentum is the high velocity of the liquid metal. Actually, it is almost impossible in complex parts exactly to figure the mold filling performance out with the experimental knowledge. The aluminum die-castings are important processes in the automotive industry to produce the lightweight automobile bodies. Due to this condition, the simulation is going to be more critical role in the design procedure. Simulation can give the best solution of a casting system and also enhance the casting quality. The cost and time savings of the casting layout design are the most advantage of Computer Aided Engineering (CAE). Generally, the relations of casting conditions such as injection system, gate system, and cooling system should be considered when designing the casting layout. Due to the various relative matters of the above conditions, product defects such as defect extent and location are significantly difference. In this research by using the simulation software (AnyCasting), CAE simulation was conducted with three layout designs to find out the best alternative for the casting layout design of an automotive Oil Pan_BJ3E. In order to apply the simulation results into the production die-casting mold, they were analyzed and compared carefully. Internal porosities which are caused by air entrapments during the filling process were predicted and also the results of three models were compared with the modifications of the gate system and overflows. Internal porosities which are occurred during the solidification process are predicted with the solidification analysis. And also the results of the modified gate system are compared.

Keywords

References

  1. Garber, L.W., Theoretical analysis and experimental observation of air entrapment during cold chamber filling, Die Casting Engineer, 1980, Vol. 24, No. 2, pp. 24-26.
  2. Hong, S.K., Series I : Melting and casting of Aluminum Alloys, Journal of The Korea Foundry Society, 2008, Vol. 28, No. 2, pp. 45-51.
  3. Information on Anycasting, http://anycastsoftware.com/en/software/fluid.php, 2013.
  4. Jang, I.K. and Lee, M.S., A Study on the advanced verified process for the optimum production of automobile parts, Methodology linking the QUEST & TimePrism, Journal of the Korea Institute of Plant Engineering, 2015, Vol. 20, No. 1, pp. 91-99.
  5. Jeon, E.K., Park, J.Y., and Park, I.M., Application Trend of Aluminum casting in Automotive Component, Journal of The Korea Foundry Society, 2007, Vol. 27, No. 1, pp. 20-23.
  6. Jeong, M.G. and Kwon, H.K., A Case Study for Developing Automobile Part (Housing) by Filling and Solidification Analysis, Journal of Society of Korea Industrial and Systems Engineering, 2015, Vol. 38, No. 1, pp. 44-51. https://doi.org/10.11627/jkise.2014.38.1.44
  7. Kim, E.S., Park, J.Y., Jeon, E.K., and Park, I.M., Current State and Technology Trend of Domestic Diecasting industry for Automotive Parts, Journal of The Korea Foundry Society, 2007, Vol. 27, No. 1, pp. 13-19.
  8. Kim, E.S., Park, J.Y., Kim, Y.H., Son, G.M., and Lee, K.H., Evaluation of Diecasting Mold Cooling Ability by Decompression Cooling System, Journal of The Korea Foundry Society, 2009, Vol. 29, No. 5, pp. 238-243.
  9. Kim, Y.C., Choi, S.W., Cho, J.I., Jeong, C.Y., and Kang, C.S., Optimization of the Thin-walled Aluminum Die Casting Die Design by Solidification Simulation, Journal of The Korea Foundry Society, 2008, Vol. 28, No. 4, pp. 190-194.
  10. Kwon, H.K. and Jang, M.K., Case Study for Developing Automobile Part(Steering Wheel) using Vacuum Die-Casting Mold, Journal of Society of Korea Industrial and Systems Engineering, 2012, Vol. 35, No. 2, pp. 195-202.
  11. Kwon, H.Y., Yoon, T.H., and Lee, B.J., Computer Simulation on the High-Pressure Die Casting(HDPC) Process by Filling and Solidification Analysis, International Journal of Applied Engineering Research, 2015, Vol. 10, No. 90, pp. 142-145.
  12. Park, J.Y., Kim, E.S., Park, Y.H., and Park I.M., Optimization of Casting Design for Automobile Transmission Gear Housing by 3D Filling and Solidification Simulation in Local Squeeze Diecasting Process, Korean Journal of Materials Research, 2006, Vol. 16, No. 11, pp. 668-675. https://doi.org/10.3740/MRSK.2006.16.11.668
  13. Park, Y.K. and Yang, J.M., Scheduling of a Casting Sequence Under Just-In-Time(JIT) Production, Journal of Society of Korea Industrial and Systems Engineering, 2009, Vol. 32, No. 3, pp. 40-48.
  14. Shin, H.W., Chung, Y.J., and Kang, S.G., A Study on Die Casting Process of the Automobile Oil Pan Using the Heat Resistant Magnesium Alloy, Journal of KSEM, 2009, Vol. 17, No. 3, pp. 45-53.