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http://dx.doi.org/10.21289/KSIC.2021.24.5.589

A Study on the Gating System and Simulation for Gravity Casting of ZnDC1 Worm Gear  

Lee, Un-Gil (School of mechanical engineering, Kyungnam University)
Kim, Jae-Hyun (School of mechanical engineering, Kyungnam University)
Jin, Chul-Kyu (School of mechanical engineering, Kyungnam University)
Chun, Hyeon-Uk (HAEAM TECH CO., LTD)
Publication Information
Journal of the Korean Society of Industry Convergence / v.24, no.5, 2021 , pp. 589-596 More about this Journal
Abstract
In this study, the optimum gating system was designed, and the two zinc alloy worm gears were manufactured in single process by applying a symmetrical gating system with 2 runners. The SRG ratio is set to 1 : 0.9 : 0.6, and the cross-sectional shapes such as sprue, runner and gate are designed. In order to determine whether the design of the gating system is appropriate, casting analysis was carried out. It takes 4.380 s to charge the casting 100%, 0.55 to 0.6 m/s at the gates and solidification begins after the casting is fully charged. The amount of air entrapment is 2% in the left gear and 6% in the right gear. Hot spots occurred in the center hole of the gear, and pores were found to occur around the upper part of the hole. Therefore, the design of the casting method is suitable for worm gears. CT analysis showed that all parts of worm gear were distributed with fine pores and some coarse pores were distributed around the central hole of worm gear. The yield strength and tensile strength were 220 MPa, 285 MPa, and the elongation rate was 8%. Vickers hardness is 82 HV.
Keywords
Casting Simulation; Gating System; Gravity Casting; Porosity;
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