• Korean Journal of Materials Research
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• v.22 no.2
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• pp.82-85
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• 2012

The effect of the alloy systems Al-Mg alloy and Al-Si alloy in this study on the characteristics of die-casting were investigated using solidification simulation software (MAGMAsoft). Generally, it is well known that the casting characteristics of Al-Mg based alloys, such as the fluidity, feedability and die soldering behaviors, are inferior to those of Al-Si based alloys. However, the simulation results of this study showed that the filling pattern behaviors of both the Al-Mg and Al-Si alloys were found to be very similar, whereas the Al-Mg alloy had higher residual stress and greater distortion as generated due to solidification with a larger amount of volumetric shrinkage compared to the Al-Si alloy. The Al-Mg alloy exhibited very high relative numbers of stress-concentrated regions, especially near the rib areas. Owing to the residual stress and distortion, defects were evident in the Al-Mg alloy in the areas predicted by the simulation. However, there were no visible defects observed in the Al-Si alloy. This suggests that an adequate die temperature and casting process optimization are necessary to control and minimize defects when die casting the Al-Mg alloy. A Tatur test was conducted to observe the shrinkage characteristics of the aluminum alloys. The result showed that hot tearing or hot cracking occurred during the solidification of the Al-Mg alloy due to the large amount of shrinkage.

• Journal of Korea Foundry Society
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• v.13 no.3
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• pp.268-275
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• 1993

In gravity die casting, die cooling systems are frequently employed with water cooling to remove the heat of the solidifying metal. Thermal modeling is an important technique in mold design for improving the productivity of the process. Computer simulation system which consists of pre-processor, main solidification simulator and post-processor has been developed for three dimensional solidification analysis of cyclic gravity die casting. The pre-processor is used for mesh generation in a PC system. The modified finite difference method is adopted for the main solidification simulation algorithm during all the casting cycles. The post-processor graphically presents the simulation results. Several experiments in automotive cast piston were carried out. The temperature variations in casting and mold with time are measured experimentally, and the results are compared with calculation results. The effects of cycle number on solidification pattern are also studied. Several experimental results for the prediction of shrinkage defects are compared with calculated results.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.32 no.3
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• pp.40-48
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• 2009

In this article, scheduling of a casting sequence is studied in a casting foundry which must deliver products according to the Just-in-time(JIT) production policy of a customer. When a foundry manufactures a variety of casts with an identical alloy simultaneously, it frequently faces the task of production scheduling. An optimal casting schedule should be emphasized in order to maximize the production rate and raw material efficiency under the constraints of limited resources; melting furnaces and operation time for a casting machine. To solve this practical problem-fulfilling the objectives of casting the assigned mixed orders for the highest raw material efficiency in a way specified by the customer's JIT schedule, we implement simple integer programming. A simulation to solve a real production problem in a typical casting plant proves that the proposed method provides a feasible solution with a high accuracy for a complex, multi-variable and multi-constraint optimization problem. Employing this simple methodology, a casting foundry having an automated casting machine can produce a mixed order of casts with a maximum furnace utilization within the due date, and provide them according to their customer's JIT inventory policy.

• Journal of Korea Foundry Society
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• v.35 no.4
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• pp.80-87
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• 2015

The Al die casting process has been widely used in the manufacturing of automotive parts when the process requires near-net shape casting and a high productive rate. However, porosity arises in the casting process, and this hampers the wider use of this method for the creation of high-durability automotive components. The porosity can be controlled by the shot condition, but, it is critical to set the shot condition in the sleeve, and it remains difficult to optimize the shot condition to avoid air entrapment efficiently. In this study, the 4.5 mm, 2.0 mm plate die castings were fabricated under various shot conditions, such as plunger velocities of 0.7 m/s ~ 3.0 m/s and fast shot set points of the cavity of -25%, 0%, 25%, and 50%. The mold filling behavior of Al melts in the cavity was analyzed by a numerical method. Also, according to the shot conditions, the results of numerical analyses were compared to those of die-casting experiments. The porosity levels of the plate castings were analyzed by X-ray CT images and by density and microstructural analyses. The effects of the porosity on the mechanical properties were analyzed by tensile tests and hardness tests. The simulation results are in good general agreements with the die-casting experimental results. When plunger velocity and fast shot set point are 1.0 m/s and cavity 25% position, castings had optimum condition for good mechanical properties and a low level of porosity.

• Journal of Korea Foundry Society
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• v.42 no.1
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• pp.61-66
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• 2022

Hydraulic units are important components of agricultural and construction machinery, and thus require high-quality castings. However, gas defects occurring inside the sand cores of the castings due to the resin used is a problem. This study therefore aimed to develop a casting simulation method that can clarify the gas defect positions. Gas defects are thought to be caused by gas generated after the molten metal fills up the mold cavity. The gas constant is the most effective factor for simulating this gas generated from sand cores. It is calculated by gas generating temperature and analysis of composition in the inert gas atmosphere modified according to the mold filling conditions of molten metal. It is assumed that gases generated from the inside of castings remain if the following formula is established. [Time of occurrence of gas generation] + [Time of occurrence of gas floating] > [Time of occurrence of casting surface solidification] The possibility of gas defects is evaluated by the time of occurrence of gas generation and gas floating calculated using the gas constant. The residual position of generated gases is decided by the closed loops indicating the final solidification location in the casting simulation. The above procedure enables us to suggest suitable casting designs with zero gas defects, without the need to repeat casting tests.

• Korean Journal of Computational Design and Engineering
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• v.17 no.2
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• pp.91-96
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• 2012

Use of casting simulation software, analyzing the reason for defect became easy. However, to create a practical solution, experienced casting expert's knowledge is always indispensable. In this study, we develop casting design automation system and the algorithm based on casting expert's knowledge, so that faster and more accurate design is enabled. Especially, to generate runner which can be shaped in numerous ways, we suggest the 'nexus' method to shape runner system.

• Journal of the Korean Society of Industry Convergence
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• v.21 no.1
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• pp.1-8
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• 2018

The purpose of this study is to develop a high-strength, high-toughness, thin-walled aluminum shock absorber housing product by applying a high vacuum die casting method to improve internal gas defect and formability. The analysis program dedicated for the casting was used because it was too costly and time-consuming to adopt the gating system design. The final casting plan was designed based on the flow pattern of the material filled into the mold and the result of air pressure and air pocket after the material was completely filled in the mold. Gaty shape was designed as a split type. The runner was designed to have the same shape as the initial inlet curve of the cavity, and the flow of the molten metal was prevented from turbulent flow. The most favorable results were obtained when the injection speed was $V_2=4.0m/s$. Defects on pores were reduced by applying high vacuum level inside the mold.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.8 no.1
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• pp.142-149
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• 1999

A machine frame has been manufactured by casting. However, due to the development of the industrial society, 3-D duties was refused. Especially, the declination of the casting industry makes it difficult to produce the frame. Many companies still manufacture the small casting products. The large casting products are extremely limited and manufactured for their own use. Therefore, it is difficult to keep the term of order. In this study, the characteristics of steel structure which is produced by welding were identified in the view of mechanical strength of steel structure which is produced by welding were identified in the view of mechanical strength to substitute steel structure for casting frame. But welding structure has the residual stress, HAZ and welding deformation. Residual stress and HAZ especially cause crack growth. The proposed steel structure, based on the simulation and experiment(tensile curve and S-N curve), can reduce not only the producting term but also the weight of the frame.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.5
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• pp.36-41
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• 2015

In this paper, research on the mold design of motor housing produced by the HPDC process was conducted using computer simulations and experiments. Recently, automobile parts have been required to be light and have high strength. The die casting process was used to manufacture automotive motor housings. In the die casting process, the control of casting defects is very important. However, it has usually depended on the experience of the foundry engineer. For the analysis of the manufacturing process of motor housing, the finite element method is applied. Through the simulations using commercial software, the filling pattern and product defects could be confirmed. The analysis results obtained from the filling behavior of the casting process agreed with the experimental results. The computer simulation results of filling behavior were reflected in the optimal mold design of motor housing.

• Journal of Korea Foundry Society
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• v.40 no.2
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• pp.34-42
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• 2020

The effects of the initial balancing pressure, filling pressure and maximum build-up pressure on the casting characteristics of the thick-wall thickness casting during the counter-pressure casting process were investigated. Water model experiment and a computer simulation were carried out to evaluate the characteristics during the filling and solidification stages in counter-pressure casting (CPC); as a reference, the low-pressure casting (LPC) process was used. The average dendrite cell size decreased with an increase in the solidification rate and maximum build-up pressure. A turbulent flow occurred during the filling stage of the LPC process, resulting in the formation of inner gas, while a lamellar flow pattern dominated during the CPC process and was more evident with an increase in the initial balancing pressure, improving the mechanical properties of the castings.