• Journal of the Korean Society for Precision Engineering
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• v.24 no.6
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• pp.131-137
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• 2007

In metal casting process, it is very difficult to predict the form accuracy of cast part and reduce repeatability error. In this study, the variations of form accuracy were measured in the process of metal cast prototyping, where RP part is manufactured from CAD model in the first, and then, wax part is cast in the vacuum environment using the RP part as master model, and finally metal prototype is cast using ceramic mold and the wax part as pattern. To investigate the variations of form accuracy, the averages and standard deviations of error distribution of the parts measured by 3D scanner were compared. It was observed that the biggest shrinkage is generated during the extraction of wax part in the second step and the biggest deterioration of form accuracy is generated during the metal part casting in the last step.

• The Journal of Korean Academy of Prosthodontics
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• v.41 no.3
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• pp.342-350
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• 2003

Statement of problem. Titanium-Nickel alloy might be used in various prosthetic restorations since it has a unique property such as super-elasticity and high fatigue resistance. However, little is known about the casting ability of this alloy. Purpose. This in vitro study compared the casting accuracy and the porosity made with different investments and various sprue designs to ascertain what casting condition would be better for the fabrication of Ti-Ni cast restorations. Material and methods. A total of 70 Ti-Ni alloy crowns were made and divided into 7 groups of 10 copings on a metal master die. For measuring the effect of the sprue numbers, two groups with one and two 8-gauge sprues were compared. Moreover, the results of the conventional sprue and the double thickness sprues were compared. Three investments were used; carbon free phosphate bonded investment, titanium investment and gypsum bonded investment. The cast restorations were evaluated at 48 points on the entire circumferential margin with a stereomicroscope measuring in micrometers. Each crown was radiographically examined for casting defects and porosity. Data on casting accuracy were analyzed using two-way and Post hoc Scheffe's comparison to determine whether significant differences existed at the 95% confidence level. Student-Newman-Keuls test were performed to identify significant differences in the number of voids. Results. The double sprueing group and double thickness group had significantly less marginal discrepancy than the single sprueing group (P<.05 and P<.01, respectively). The castings with phosphate bonded investment showed the least marginal discrepancy and the smoothest surface. The castings invested in the gypsum bonded investment had the greatest gaps in margin and the largest failure rate. The double sprueing group and phosphate bonded investment group had significantly smaller void numbers and smaller void size than the other groups. Conclusion. Within the limitations of this in vitro study, the casting accuracy of the groups using thicker, double sprue design and the phosphate bonded investment was significantly superior. Moreover, void number and size were less than other groups.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.1
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• pp.30-37
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• 2000

In this paper rapid prototyping and precision casting technology have been developed for the manufacturing of inlet gear box of an airplane, Rapid prototyping is a new prototyping technology that produces complicated parts directly from three-dimensional CAD data with a high efficiency and has been extensively applied to various manufacturing processes. In the present work Selective Lase Sintering(SLS) system is utilized in order to manufacture prototype of the inlet gear box. Prototyping technology using SLS is also investigated from the viewpoint of accuracy. Using the SLS master the casting products are manufactured through several processes such as : vacuum casting lost wax shell casting and investment cast-ing. The shrinkage characteristics of wax and cast iron in the casting procedures are considered and then reflected to the design procedure so that the accuracy of the product is improved consequently.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.616-619
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• 2002

Spin casting is one of useful methods to manufacture metal parts with low mold cost and short delivery time. But the silicon rubber based conventional method has several problems such as poor dimensional accuracy, limitation in casting materials and its dependency on speciality in meld making process. To solve those problems, this paper suggests a steel based mold making method using direct CNC machining and the experimental results shows that the parts from the developed method has better dimensional accuracy and surface roughness than those from the conventional method.

• 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.

• Journal of Technologic Dentistry
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• v.30 no.2
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• pp.57-63
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• 2008

Statement of problem: Conventional techniques for implant framework fabrication produce significant error that is inconsistent with passive-fit requirement for osseointegrated implants. One of the etiologic factors which cause the errors is a sprue which may deform the framework during solidification and contraction. Purpose: This study was aimed to evaluate objectively effect of the sprue design on the accuracy of fit of implant prosthesis. Materials and method: Three different designs were considered relative to effect of casting accuracy. The first design had straight sprues and a button of excess alloy at the non-casting end of the sprues. The second was runner bar design(with the button). The last was straight sprues design(without the button). Gold cylinder and laboratory analogue had been used to diminish variables affecting to casting accuracy. Gold alloy and pressure-vacuum casting machine had been used. Marginal gap had been measured by SEM. One-way ANOVA and Duncan test had been used for statistical analysis. Results: The first design showed $79.87{\pm}13.95{\mu}m$ marginal gap. The second and third were $40.17{\pm}15.8{\mu}m$ and $35.17{\pm}9.95{\mu}m$ respectively. Conclusion: Straight sprues without button and runner bar designs were more accurate than straight sprues with button design(P<.05).

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.6
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• pp.54-60
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• 2014

In industry, several casting process are widely used to manufacture complex and accurate blank part of hard materials such as aluminum, casting steels, bronze and magnesium alloys which are difficult to manufacture in a blank shape. Even if the casting process does not high accuracy superior surface characteristics other machining process, the casting process is widely used in manufacturing blank part. Furthermore, it is difficult to select appropriate casting process a part among several casting process. for effective selection different process, a careful decision given casting application is necessary. An appropriate casting for a given material and shape condition must be selected for novice engineers in industry. In this paper, an expert system based on an analytic network process(ANP) is suggested for best selection of casting considering a prior interdependency effect among various factors such as material, geometry, process capability, economy and equipment.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.453-456
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• 2000

This paper presents experimental results on selecting optimal process parameters for UV-Vaccum casting. The UV-Vacuum casting is a relatively new process that allows very rapid mold preparation and part duplication via UV curing. Effect of various process variables such as pressure and temperature on mold strength and part accuracy was evaluated by using Taguchi method.

• Journal of Korea Foundry Society
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• v.18 no.3
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• pp.246-253
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• 1998

Precision metal mold casting process is a casting method manufacturing mechanical elements with high precision, having heavy/light alloys as casting materials and using permanent mold. To improve dimensional accuracy and the final mechanical properties of the castings, the solidification speed and the cooling rate of the casting should be controlled with the optimum mold cooling system, and moreover, to obtain more accurate control of the whole process interfacial heat transfer characteristic at the mold/casting interface must be studied in advance. In the present study, aluminum alloy casting system with metal mold equipped with electrical heating elements and water cooling system was designed and the temperature histories at points inside the metal mold were measured during the casting process. The heat transfer phenomena at the mold/casting interface was characterized by the heat flux between solidifying casting metal and metal mold, and the heat flux history was obtained using inverse heat conduction method. The effect of mold cooling condition upon the heat flux profile was examined, and the analysis shows that the heat flux value has its maximum at the beginning of the process.

• 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.