• Title/Summary/Keyword: Aluminum die casting process

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Analysis and Design of Alternator Housing for Automobile (자동차용 알터네이터 하우징의 성형해석 및 금형설계)

  • 조영석;박종배;한규택;정영득
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 2002.04a
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    • pp.3-7
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    • 2002
  • The die casting process was used to manufacture a alternator housing for automobile. Specially automobile parts were required light and hight strength. Therefore simulation have been carried out die casting process of the alternator housing. In this paper, we investigated about characteristics of the die casted alternator housing the HPDC(High Pressure Die Casting) process. Also we designed the die casting die with the simulation results of the alternator housing. The MAGMAsoft and Auto-CAD was used as computer simulation and design code and used material was ADC12(Aluminum Die Casting Alloy). We present the results of filling behavior and design of die process of the alternator housing cast. The result obtained about filling behavior and design of die of the cast showed good agreement with test result.

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Die Casting Analysis of Motor Housing for Automobile (자동차용 모터하우징에 관한 다이캐스팅 성형해석)

  • 문찬용;박종배;정원영;한규택;정영득
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2002.05a
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    • pp.769-773
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    • 2002
  • The die easting process was used to manufacture a motor housing for automobile. Specially automobile parts were required light and high strength. Therefore simulations have been carried out die casting process of motor housing. In this paper, we investigated about characteristics of the die casted motor housing with HPDC(High Pressure Die Casting) process. Also the MAGMAsoft was used as computer simulation code and used material was ADC12(Aluminum Die Casting Alloy). We present the results of filling behavior and solidification process of a motor housing cast. The analysis results obtained about filling behavior and solidification of cast showed good agreement with test results.

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Evaluationof Exposure Levels and Detection Rate of Hazardous Factors in the Working Environment, Focused on the Aluminum Die Casting Process in the Automobile Manufacturing Industry (자동차 부품제조 사업장의 유해인자 노출 농도수준 및 검출율 - 알루미늄 다이캐스팅 공정을 중심으로 -)

  • Lee, Duk-Hee;Moon, Chan-Seok
    • Journal of Korean Society of Occupational and Environmental Hygiene
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    • v.28 no.1
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    • pp.100-107
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    • 2018
  • Objectives: This study examines exposure to hazardous substances in the working environment caused by exposure to toxic substances produced in the aluminum die casting process in the automobile manufacturing industry. Materials and Methods: The exposure concentration levels, detection rates and time-trend of 15 hazardous factors in the aluminum die casting process over 10 years(from 2006 to 2016) were used as a database. Results: The study found that hazardous factors in the aluminum die casting process were mostly metals. The rate for detected samples was 70.6%(405 samples), and that for not detected samples was 29.4%. The noise for an eight-hour work shift showed a 49.7% exceedance rate for TLV-TWA. Average noise exposure was 89.0 dB. The maximum exposure level was 105.1 dB. Conclusion: The high numbers of no-detection rates for hazardous substance exposure shows that there is no need to do a work environment measurement. Therefore, alternatives are necessary for improving the efficiency and reliability of the work environment measurement. Moreover, to prevent noise damage, reducing noise sources from automation, shielding, or sound absorbents are necessary.

Strength Analysis of Aluminum Alloy Window Wiper Manufactured by Die Casting (다이캐스팅용 알루미늄 합금으로 제작된 윈도우 와이퍼의 강도 해석)

  • Cho, Seunghyun;Lee, Jeungho;Kim, Hangoo
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.25 no.3
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    • pp.204-210
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    • 2016
  • This study analyzed the amount of displacement of window wipers according to pressure by using finite element analysis (FEA) with KS standards for aluminum alloy window wipers manufactured by die-casting method. The product design was changed over four steps considering the die-casting process to achieve strength greater than that of the conventional steel window wiper. According to the FEA results, the strength of final aluminum alloy window wiper improved by 55% over that of a steel window wiper, and the weight of the former was less by approximately 45%. Therefore, there is the possibility of module downsizing for driving motor capacity. Further, the cost competitiveness improved, and the manufacturing process of aluminum alloy window wipers was simplified.

3D scanning based mold correction for planar and cylindrical parts in aluminum die casting

  • Seno, Takashi;Ohtake, Yutaka;Kikuchi, Yuji;Saito, Noriaki;Suzuki, Hiromasa;Nagai, Yukie
    • Journal of Computational Design and Engineering
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    • v.2 no.2
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    • pp.96-104
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    • 2015
  • Aluminum die casting is an important manufacturing process for mechanical components. Die casting is known to be more accurate than other types of casting; however, post-machining is usually necessary to achieve the required accuracy. The goal of this investigation is to develop machining- free aluminum die casting. Improvement of the accuracy of planar and cylindrical parts is expected by correcting metal molds. In the proposed method, the shape of cast aluminum made with the initial metal molds is measured by 3D scanning. The 3D scan data includes information about deformations that occur during casting. Therefore, it is possible to estimate the deformation and correction amounts by comparing 3D scan data with product computer-aided design (CAD) data. We corrected planar and cylindrical parts of the CAD data for the mold. In addition, we corrected the planar part of the metal mold using the corrected mold data. The effectiveness of the proposed method is demonstrated by evaluating the accuracy improvement of the cast aluminum made with the corrected mold.

Durability Analysis of Aluminum Alloy Brake Pedal Manufactured by Die Casting (다이캐스팅용 알루미늄 합금 브레이크 페달의 내구성 해석)

  • Cho, Seunghyun;Kang, Seul-Ki;Kim, Hangoo
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.25 no.3
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    • pp.198-203
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    • 2016
  • Computer-Aided Engineering (CAE) durability analysis and experiments of an aluminum alloy brake pedal were carried out for the car lighter by die casting method. In the CAE analysis, KS standards and criteria of the Volvo Car Corporation were applied, and in the experiment, KS standards were applied. The CAE analysis results show that aluminum alloy brake pedals are stronger than the conventional steel brakes pedals because the yield strength of the aluminum alloy increased by almost 97% over that of steel. Further, the structures of the cylinder and the frame were reinforced with increasing thickness of flame and were changed to suit the die-casting process. Through a durability test based on the KS standard, the strength of a prototype of the aluminum alloy brake pedal was confirmed to be sufficient.

Development of High Quality Die Casting Technology with Function to Purify Molten Metal (용탕청정기능을 부여한 고품질 다이캐스팅 기술의 개발)

  • Hatano, Tomoyuki;Takagi, Hiromi;Inagaki, Mitsugi
    • Journal of Korea Foundry Society
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    • v.24 no.1
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    • pp.3-9
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    • 2004
  • Die casting is "a process in which molten metal is injected at high velocity and pressure into a mold(die) cavity". Casting with smooth surfaces, high dimensional precision, complicated shapes, and reduced weight can be obtained using this process. But this process is susceptible to casting defects such as porosities, scattered chilled layers, hard spots, etc. For preventing casting defects, we developed "low-velocity high pressure die casting technology", "squeeze die casting technology", "heat insulating sleeve lubricant technology", and "direct pouring technology". The "direct pouring technology" is useful for producing molten metal without oxide contamination. It consists of a pumping system which supplies pure molten metal to the die casting machine. By using this technology, we have successfully reduced oxide contamination in castings to 1/20 of that of our previous castings.

The Effect of Plunger Tip Shape on the Formability in Semi-Solid Die Casting Process (반용융 다이캐스팅 공정에 있어서 플런저 팁의 형상이 성형성에 미치는 영향)

  • 서판기;손영익;강충길
    • Transactions of Materials Processing
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    • v.11 no.4
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    • pp.312-322
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    • 2002
  • In this study, an innovative semi-solid die casting technology to replace heavier cast iron compressor parts with lightweight aluminum castings was proposed, and the application possibility for home-appliance component was investigated. The most important factors regarding the semi-solid die casting process are the reheating process of the raw materials to the semi-solid state, specifications of the forming machine, the optimal injection conditions and die design. Materials used in this study were A3S7 and hSn alloys fabricated by the electromagnetic stirring process. The optimal injection conditions for semi-solid die casting process were Presented with the reheating conditions of the semi-solid materials. To investigate the effect of plunger tip shape on the formability and mechanical properties in semi-solid die casting process for complicated shape part, two kinds of plunger tip shape with long and short plunger tip taper are proposed.

The Effect of Velocity Control Method on the Part Characteristic in Semi-Solid Die Casting (반용융 다이캐스팅 공정에 있어서 속도제어방법이 제품의 특성에 미치는 영향)

  • Seo, Pan-Ki;Kang, Chung-Gil;Son, Young-Ik
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.26 no.10
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    • pp.2034-2043
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    • 2002
  • The process design to produce a near net shape home-appliance compressor component using semi-solid die casting process is performed. In order to obtain a good component without defects such as liquid segregation and porosity, the relationship between pressure and time, and plunger tip displacement and injection velocity are proposed with repeated trial and error. The effect of the velocity variation in the process parameters on liquid segregation and extraction is investigated to produce the aluminum frame part(a kind of compressor part) with good mechanical properties. The mechanical characteristic of semi-solid die casting formed parts for AlSi7Mg0.65r(A357) and AlSi17Cu4Mg(A390) are investigated with a view to minimizing the occurrence of defects. To investigate of application possibility at industry field, A380 aluminum alloy with 8∼9% silicon contents used for the squeeze casting process. The obtained mechanical properties is compared with semi-solid die casting.