• 한국기계가공학회지
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• 제16권4호
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• pp.104-112
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• 2017

In the sand casting process, the flow of liquid metal affects the quality of casting products and their die life. To determine the optimal bush part design process, this study performed various analyses using commercial finite element analysis S/W. The simulation focused on the molten metal behaviors during the mold filling and solidification stages of sand casting. This study aims to develop methods to reduce the cost and increase the tool life of the continuous hot zinc plating roll.

• 한국정밀공학회지
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• 제17권11호
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• pp.122-128
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• 2000

In this paper, a bulging condition which affect the quality of continuous casting steel was analyzed by using the numerical analytic method. First, solidification analyses were performed for each cooling zone by one-dimensional finite difference method. The bulging deformation of cast slab has been calculated with a two-dimensional elasto-plastic and creep finite element model. The adequacy of the model has been checked against the experimental results. From this study the effects of the process variables such as casting speed, cooling condition and roll pitch were examined. The results from these analyses would be able to apply to the design of continuous casting process.

• 한국주조공학회지
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• 제38권1호
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• pp.9-15
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• 2018

Electromagnetic continuous casting (EMCC) was used to fabricate Ti-6Al-4V alloys with properties suitable for medical applications. Ti-6Al-4V alloy ingots fabricated by EMCC were subjected to heat treatment, such as residual stress removing (RRS), furnace cooling after solution treatment (ST-FC) and water-cooling after solution treatment (ST-WC), in order to obtain characteristics suitable for the standard. After component analysis, the microstructure and mechanical properties (tensile strength and elongation) were evaluated by ICP, gas analysis, OM, SEM, a Rockwell hardness tester and universal testing machine. The Ti-6Al-4V alloy ingot fabricated by EMCC was fabricated without segregation, and the lamellar structure was observed in the RRS and ST-FC specimens. The ST-WC specimen showed only martensite structure. As a result of evaluating the mechanical properties based on the microstructure results, we found that the water-cooled heat treatment condition after the solution treatment was most suitable for the Ti-6Al-4V ELI standard.

• 한국산업융합학회 논문집
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• 제24권5호
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• pp.589-596
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• 2021

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.

• 한국산업융합학회 논문집
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• 제24권5호
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• pp.597-608
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• 2021

The control head components used in small military vessels are designed to be domestically produced, prototypes, structural analysis, and casting methods are designed and cast. The control head assembly consists of a lever, an aluminum outside cover, Middle, front gear cover, back gear cover, and a zinc worm gear. In order to reverse the design of each component, 3D scanning device was used, 3D modeling was performed by CATIA, and prototype productions were carried out by 3D printer. In order to reduce the cost of components, gating system is used by gravity casting method. The SRG ratio of 1:0.9:0.6 was set by applying non-pressurized gating system to aluminum parts, 1:2.2:2.0 and pressurized gating system to zinc parts, and the shapes of sprue, runner and gate were designed. The results of porosity were also confirmed by casting analysis in order to determine whether the appropriate gating system can be designed. The results showed that all parts started solidification after filling completely. ANSYS was used for structural analysis, and the results confirmed that all five components had a safety factor of 15 more. All castings are free of defects in appearance, and CT results show only very small porosity. ZnDC1 zinc alloy worm gear has a tensile strength of 285 MPa and an elongation of 8%. The tensile strength of the four components of A356 aluminum alloy is about 137-162 MPa and the elongation is 4.8-6.5%.

• 헤리티지:역사와 과학
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• 제53권2호
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• pp.4-23
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• 2020

이 연구는 우리나라 철 주조기술의 다양성과 기술 체계를 규명하기 위한 목적으로 진행되었으며, 이를 위해 고문헌 조사 및 유물 분석, 제작 도구와 제작 기술에 대한 현지 조사 그리고 주조와 거푸집에 사용된 재료의 과학 분석 등을 실시하였다. 불미기술은 송풍구인 풀무를 이용하여 주철을 녹인 뒤 그 쇳물을 토제 거푸집에 부어 주물을 완성하는 철 주조기술로 현재 유일하게 제주도에서만 전승되고 있는데, 모래 거푸집을 사용하는 육지와 비교해 토제 거푸집을 사용하고 있다는 것이 큰 차이점이라 할 수 있다. 무쇠솥 주조기술에는 석비레, 모래, 점토 등을 섞어 만든 모래 거푸집을 이용한 주물사주조법(鑄物砂鑄造法)과 점토에 볏짚과 갈대 등을 섞어 만든 토제 거푸집을 이용한 도토주조법(陶土鑄造法)이 사용되고 있다. 주물사주조법에 의한 무쇠솥 주조는 거푸집 만들기, 속심 제작, 쇳물 작업, 거푸집에 쇳물 붓기, 완성품 다듬기 등 5단계의 작업공정을 거치며, 도토주조법에 의한 무쇠솥 주조는 거푸집 만들기, 거푸집 굽기, 질먹 입히기, 쇳물 작업, 쇳물 붓기, 완성품 다듬기 등 크게 6단계의 작업 공정으로 이루어진다. 두 주조법은 거푸집의 재료, 거푸집을 불에 굽고 질먹을 입히는 제작 공정에서 차이를 보인다. 이번에 연구한 불미기술은 토제 거푸집 무쇠솥 주조로 진흙 채취 및 반죽, 거푸집 제작, 초벌 굽기, 화적모살 및 질먹 바르기, 건조 및 비얄질, 거푸집 합장, 둑(용광로)제작, 재벌 굽기, 제련, 쇳물 붓기, 주물 다듬기 등 단계별 주조 공정에 사용된 재료 및 도구 분석과 제작 기술에 담겨진 과학 기술 원리를 규명하여 우리 고유 철 주조기술의 기술 체계를 밝혀 보았다. 그리고 무쇠솥 도토주조를 위해 이용한 재료와 완성품을 과학 분석한 결과, 거푸집은 주성분이 SiO₂, Al₂O₃, Fe₂O₃으로 이루어진 진흙과 모래이고, 이형재는 SiO₂, Al₂O₃, Fe₂O₃, K₂O가 함유된 흑연이며, 완성된 무쇠솥의 미세 조직은 시멘타이트(Fe₃C)와 펄라이트(페라이트와 시멘타이트의 층상 구조)로 이루어진 백주철 조직임을 확인하였다.

• 박물관보존과학
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• 제15권
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• pp.4-25
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• 2014

국립춘천박물관이 소장하고 있는 수다사지 청동금고는 1987년 강원도 평창군 진부면 수항리에서 발견되었다. 금고 표면에, 제작 당시의 주조 결함과 보수 흔적이 다수 발견되어 제작 기법을 유추하기에 용이한 중요 자료이다. 본 연구에서는 금고의 성분, 주형과 채플릿^{Chaplet, 형지(型持), 코어받침쇠}의 위치, 결함의 원인 등을 과학적으로 조사하여 주조 기법과 당대의 보수 방식을 추정해 보았다. 성분 분석 결과, 금고의 주성분은 구리 71.6wt%, 주석 18.2wt%, 납 7.2wt%로 3원계 청동합금이며 비소·안티몬이 각각 약 1wt%씩 검출되었다. 주조 시 주형을 고정하기 위하여 사용한 채플릿의 성분은 납 함량이 금고보다 더 높으며, 제작 후 구멍을 메우기 위해 사용된 땜납의 성분은 납 함량이 가장 높게 나타났다. 주조 분할선을 토대로 표면 상태를 관찰한 결과 사형주조 ^砂型鑄造로 제작되었을 가능성이 높았으며, 표면 관찰 및 방사선투과조사로 냉접^{Cold shut}이나 표면 주름^{Surface Folds}, 미스런^Misrun, 채플릿 주변의 기공^{Blowholes Adjacent to Chaplets} 등의 주조결함을 확인하고 발생 원인을 추정하였다. 보수된 부분은 제작 당시의 주조 결함인 구멍이 생긴 부위를 메우기 위하여 연납을 사용한 땜질보수 ^{Soldered-in Repair}를 하였다.

• 한국주조공학회지
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• 제43권6호
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• pp.302-309
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• 2023

일반적으로 주조품은 복잡한 형상을 가지고 있고, 한 제품 내에서 두께의 차이가 현저하게 나는 경우가 있어 시뮬레이션을 위한 격자를 생성할 때 어려움이 있다. 주조 유동은 이상유동으로 수치해석을 할 때 공기와 용탕의 경계면을 추적해야하며 밀도차에 의한 압력장 계산에 많은 시간이 소요된다. 이와 같은 이유로 주조유동해석에는 직교격자가 주로 이용되어왔다. 그러나 직교격자는 형상을 제대로 표현하지 못한다. 곡면에서 나타나는 계단형상 격자로 인해 모멘텀 손실이 발생하고 이로 인해 용탕의 흐름이 달라질 수 있으며 결과적으로 잘못된 주조 방안 설계를 할 수 있다. 이를 피하기 위하여 직교격자계에서 형상을 좀 더 정확하게 표현하기 위하여 많은 수의 격자를 생성하여 해석을 한다. 또는 직교격자계에서 발생하는 문제를 수치적으로 보완하는 Cut Cell 방법을 적용하여 해석하는 방법이 있다. 본 연구에서는 직교격자계에서 주조유동해석을 할 때 격자수에 따른 해석결과와 Cut Cell 방법을 적용한 해석 결과를 비교하였다. 또한 주조공정별로 실제제품을 주조유동해석을 하고 공정별로 Cut Cell 방법을 적용한 결과를 고찰하였다.

• Advances in concrete construction
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• 제10권5호
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• pp.455-462
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• 2020

This study investigated the effect of horizontal casting joints on the mechanical properties and structural behavior of sustainable self-compacting reinforced concrete beams (SCRCB). The experimental research consisted of two stages. The first stage used four types of concrete mixtures which were produced to indicate the effects of cement replaced with cement waste at 0%, 5%, 10%, and 15% by weight of cement content on fresh concrete properties of self-compacting concrete (SCC) such as, passing ability, filling ability, and segregation resistance. In addition, mechanical properties such as compressive, tensile, and flexural strength were also studied. The second stage selected the best mixture from the first stage and studied the effect of horizontal casting joints on the structural behavior of sustainable SCRCBs. The effect of horizontal casting joints on the mechanical properties and structural behavior were at the 25%, 50%, 75%, and 100% of sample height. Load deflection, failure mode, and theoretical analysis were studied. Results indicated that the incorporation of replacement with cement waste by 5% to 10% led to economic and environmental advantages, and the results were acceptable for fresh and mechanical properties. The results indicated that delaying the time for casting the second layer and increasing the cement waste in concrete mixtures had a great effect on the mechanical properties of SCC. The ultimate load capacity of horizontal casting joints reinforced concrete beams slightly decreased compared with the control beam. The maximum deflection of casting joint beams with 75% of samples height is similar with the control beam. The experimental results of reinforced concrete beams were substantially acceptable with the theoretical results. The failure modes obtained the best forced casting joint on the structural behavior at 50% height of casting in the beam.

• 열처리공학회지
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• 제27권6호
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• pp.281-287
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• 2014

Microstructural and mechanical characteristics of Al-6Si-2Cu alloy for engine mount bracket prepared by gravity casting (as-cast) and die-casting (as-diecast) process have been investigated. For the microstructural characterization, the inductively coupled plasma mass spectrometry (ICP-MS), optical microscope (OM), scanning electron microscope (SEM) and electron probe microanalysis (EPMA) analyses are conducted. For the intermetallic phases, the X-ray diffraction (XRD) and energy dispersive spectroscopy (EDS) are also conducted with quantitative and qualitative analysis. Micro Vickers hardness and static tensile test are achieved in order to measure mechanical properties of alloys. Secondary dendrite arm spacing (SDAS) of as-cast and as-diecast show 37um and 18um, respectively. A large amount of coarsen eutectic Si, $Al_2Cu$ intermetallic phase and Fe-rich phases are identified in the Al-6Si-2Cu alloy. Mechanical properties of gravity casting alloy are much higher than those of die-casting alloy. Especially, yield strength and elongation of gravity casting alloy show 2 times higher than die-casting alloy. After shot peening, shot peening refined the surface grains and Si particles of the alloys by plastic deformation. The surface hardness value shows that shot peening alloy has higher value than unpeening alloy.