• 연구논문집
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• 통권29호
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• pp.173-183
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• 1999

The vacuum investment casting process for a large gas turbine component, Inner Preswirl Support (IPS), was simulated by using commercial FEM package ProCAST(TM) with view factor radiation method. The solid fraction in mushy zone was directly measured by Differential thermal analysis(DTA-DSC mode). Three types gating design. considering liquid flow and heat release through it. were proposed. Solidification had begun at the ribs or thin sections of the IPS casting and advanced further through the upper and lower gates. The computed temperature gradient G and G/R values at 70% solidified temperature were used for prediction of microshrinkage formation during casting. The effect of mold preheat on the thermal history of the casting displayed minute effect on the microshrinkage formation.

• 한국주조공학회지
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• 제9권1호
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• pp.39-48
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• 1989

A basic three dimensional thermal model has been developed to simulate the solidification sequence for gravity die casting process. The finite difference method was used to analyze the solidification process during all the casting cycles. The prediction of die temperature in the quasi-steady state was analyzed by the boundary element method. The influence of die cooling on the heat flow in the cast/mold system was also investigated. Predictions of the computer simulation on temperature profiles and location of shrinkage defects were in good agreement with those observed in experimental die castings. Models of computer simulation which is developed by this work can be useful for the design and process control of die casting.

• 한국주조공학회지
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• 제24권6호
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• pp.347-355
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• 2004

In the die casting process, the flow of liquid metal has significant influence on the quality of casting products and die life. For the optimal process design of automobile gear housing, various analyses were performed in this study by using computer simulation code, MAGMAsoft. The simulation has been focused on the molten metal behaviors during the mold filling and solidification stages for the sound casting products. Also the internal defects were predicted by application of air pressure and feeding criteria.

• 대한금속재료학회지
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• 제50권2호
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• pp.129-135
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• 2012

High speed casting technology is an attractive method to increase the productivity of continuous casting. However, high speed casting causes flow instability of molten steel in a mold. In this study, Large Eddy Simulation (LES) has been performed to identify the characteristics of mold flow for various shapes of submerged entry nozzles. The LES code has been newly developed to efficiently compute the two-phase flow by using the Fractional Step Method (FSM) combined with the Volume of Fluid (VOF) method. The Immersed Boundary Method was used to implement the shape of the submerged entry nozzle. Three cases of discharge angle of the submerged entry nozzle were computed and compared. The current results shed light on improving shape design of a submerged entry nozzle.

• 한국정밀공학회지
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• 제18권9호
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• pp.101-109
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• 2001

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. Because of lower mechanical properties induced by the large grain structure and incomplete filling, conventional plaster casting is not suitable for the simulated die casting process. A plaster casting process with pressurized vibration was developed for the simulated die casting process[5]. In this paper, numerical simulation for the filling stage of the process has been performed to show the effect of the pressurized vibration for complete filling. Treatment of boundary condition based on the finite element method has been proposed for imparted pressurized vibration in the plaster casting process.

• 산업경영시스템학회지
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• 제35권4호
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• pp.179-185
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• 2012

When manufacturing die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize casting design of an automobile part (Gear Box) Computer Aided Engineering (CAE) was performed by using the simulation software (Z Cast). The simulation results were analyzed and compared with experimental results. During the mold filling, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system. For making a better production die casting tool, cooling systems on several thick areas are proposed in order to reduce internal porosities caused by the solidification shrinkage.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2005년도 춘계학술대회 논문집
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• pp.174-179
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• 2005

In the super slow speed die casting process, the casting defects due to melt flow should be controlled in order to obtain sound casting products. The casting defects that are caused by molten metal were cold shut formation, entrapment of air, gas, and inclusion. But the control of casting defects has been based on the experience of the foundry engineers. The calculation of simulation can produce very useful and important results. The calculation data of die casting process condition from the computer simulation by the Z-CAST is made to insure that the liquid metal is injected at the right velocity range and that the filling time is small enough to prevent premature solidification. The parameters of runner shape that affected on the optimized conditions that was calculated with simple equation were investigated. These die casting process control techniques of automobile valve body mid-plate have achieved good agreement with the experimental data of tensile strength, hardness test, and material structure photographies satisfactory results.

• 한국주조공학회지
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• 제32권2호
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• pp.65-74
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• 2012

In this paper, we present the results of our studies on optimal die design towards development of a vacuum die casting process to fabricate fuel cell bipolar plate with micro-channel array. Cavity and overflow shape is designed by computational filling analysis of MAGMA soft. Optimal die design consists of seven overflows at the end of cavity and three overflows at each side wall of cavity. The molten metal that passed the gate and reached the side wall flowed into the side overflow, no turbulent flow occurred, and the filling behavior and velocity distribution were uniform. In addition, partially solidified molten metal passing through the channel was perfectly eliminated by overflow without back-flow. When vacuum pressure, injection speed of low and high region was 300 mbar, 0.3 m/s and 2.5 m/s respectively with Silafont 36 die casting alloy, sound sample without casting defects was obtained. The experimental results are nearly consistent with simulation results.

• Korea-Australia Rheology Journal
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• 제13권3호
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• pp.131-139
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• 2001

A coupled approach is proposed for the prediction of sheet profile in sheet casting process, which combines one-dimensional analytical method on planar elongational flow region and three-dimensional numerical method on the other region. The strategy is constructed from the observations that the flow domain of sheet casting process can be separated into two parts based old the flow kinematics. The flow field in the central region of sheet, over which the planar elongational flow dominates, is possibly replaced by one-dimensional analytical solution. Then only a partial flow domain near the edge region of sheet, where the flow kinematics cannot be described by the planar elongational flow itself, requires three-dimensional numerical simulation. Good agreement is observed between the coupled approach developed in this study and the full three-dimensional numerical simulation previously developed and reported by the authors. This coupled approach may have provided flexibility with low costs to accommodate a wide range of die sizes in sheet casting process.

• 한국주조공학회지
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• 제20권6호
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• pp.400-406
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• 2000

Computer simulation for the predictions of casting defects is very important to produce high quality castings with less cost. Complicate shaped Al solenoid housing part was selected to be cold chamber die cast and a numerical simulation technique was applied for the optimization of the chill vent position and gating. A first design led to insufficient central flow. This flow left the last filled areas falling into the inner portion of the part. And last filled area did not fit the chill vent position. So these resulted in a high possibility of air entrapment in the casting and the design was not proper for the part. The design was improved by using a proper gating system, a more chill vent and proper overflow positions. New design provided a homogenous mold filling pattern and the last filled areas that being located at the overflow and chill vent. Casting plan which produce good quality solenoid housing part was established by using the computer simulation.