• Journal of Korea Foundry Society
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• v.35 no.2
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• pp.29-35
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• 2015

In this study, potential defects of ring-type cast products during the mold-filling stage of the casting process were investigated using computer simulation. The main focus was on the effects of runner extension and ingates. During the mold filling the molten metal flowed from the bottom to the top of the mold in two curved paths along the ring-type cavity. The fluid fronts in the two paths did not show the identical velocity during the mold filling stage. This difference in the filling speeds may cause defects such as voids and local contractions. The present model contained virtual fluid detectors at various positions inside the mold. When the molten metal passed those points, the volume of fluid jumped up from zero to one. The moments were measured to compare the speeds of the fluid fronts. We attempted various combinations of runner extensions and ingates to stabilize the flow and then to optimize the casting mold design.

• Journal of Korea Foundry Society
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• v.29 no.1
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• pp.33-37
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• 2009

Cartesian grid system has mainly been used in the casting simulation even though it does not nicely represent sloped and curved surfaces. These distorted boundaries cause several problems. A special treatment is necessary to clear these problems. In this paper, we propose a new method that can consider the cutting cells which are cut by casting and mold based on the partial cell treatment (PCT). This method provides a better representation of geometry surface and will be used in the computation of velocities that are defined on the cell boundaries in the Cartesian grid system. Various test examples for several casting process were computed and validated. The analysis results of more accurate fluid flow pattern and less momentum loss owing to the stepped boundaries in the Cartesian grid system were confirmed. By using the cut cell method, performance of computation gets better because of reducing the whole number of meshes.

• 한국전산유체공학회:학술대회논문집
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• 2011.05a
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• pp.518-522
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• 2011

Cartesian grid system has mainly been used in the casting simulation even though it does not nicely represent sloped and curved surfaces. These distorted boundaries cause several problems. A special treatment is necessary to clear these problems. A cut cell method on Cartesian grids has been developed to simulate three-dimensional mold filling Cut cells at a cast-mold interface are generated on Cartesian grids. Governing equations were computed using volume and areas of cast at cut cells. In this paper, we propose a new method that can consider the cutting cells which are cut by casting and mold based on the patial cell treatment (PCT). This method provides a better representation of geometry surface and will be used in the computation of velocities that are defined on the cell boundaries in the Cartesian gird system. Various test examples for several casting process were computed and validated. The analysis results of more accurate fluid flow pattern and less momentum loss owing to the stepped boundaries in the Cartesian grid system were confirmed. We can know the momentum energy at the cut cell is conserved by using the cut cell method. By using the cut cell method. performance of computation gets better because of reducing the whole number of meshes.

• Journal of Korea Foundry Society
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• v.33 no.5
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• pp.204-209
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• 2013

The family mold casting have advantages which are able to make products with different shapes and dimensions simultaneously in a single mold. In this study, the design of the 4 cavity rotor family mold was used by "Anycasting" software, the defects occurred during die casting were predicted and suggested the best optimization conditions for sound products. The result of the experiment were that the optimum overflow design was needed for gas emission and control of residual oxides. It was clear that the defects positions formed by diecasting were agreed with nearly them predicted by simulation.

• Journal of Korea Foundry Society
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• v.22 no.1
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• pp.26-34
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• 2002

For application of cast-forging process with Al-Si alloys, casting experiments are carried out by adding Sr and TiB to Al-Si alloys for grain refinement treatment. We experimented on the mechanical properties according to microstructural changes, forging ability test and also investigated the mechanical properties after forging. The finest microstructure could be observed respectively when 0.05 wt.%Sr and 0.1 wt.%TiB were added. In this case, tensile strength and elongation increased much more than as casting. After high temperature deformation simulation test with grain refinement specimens was carried out, about 60N per unit $area(mm^2)$ of specimen was confirmed. After hot forging, tensile strength and elongation were increased. It was considered that casting defect was removed by compressive working.

• Transactions on Control, Automation and Systems Engineering
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• v.1 no.1
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• pp.1-7
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• 1999

This paper gives a simulation study of a new fuzzy logic control(FLC) approach for the mold level control in continuous casting processes. The proposed FLC is PID type hybridizing the conventional fuzzy PI control and Fuzzy PD control with a simplified design scheme. It is shown that, compared with the conventional control, this new control strategy can achieve superior performance for steady-state response and is more robust against process parameter variations and disturbances.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.10a
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• pp.138-141
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• 1997

CFM(Cast Forge Method) is widely used in manufacturing industry to produce aluminium parts with good mechanical properties and low production cost. CFM is the process which produces a final products by forging from the initial billet by casting. The study on this paper covers the automatic design method which finds a pertinent shape for initial billet using Fast Fourier Transform, low-pass frequency filtering and FEM simulation of the nonisothermal forging process by DEFORM. These works will give us an information to enhance the low strength of a aluminium casting.

• Journal of Korea Foundry Society
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• v.24 no.5
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• pp.281-289
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• 2004

The present study focused on the estimation of the interfacial heat transfer coefficient as a function of the surface temperature of the aluminum casting at the mold/casting interface to investigate the effects of superheat and coating layer. The casting experiments of aluminum into a cylindrical copper mold were systematically conducted to obtain the thermal history during solidification. The thermal history recorded by four thermocouples embedded both in the mold and the casting was used to solve the inverse heat conduction problem using Beck's method. The effects of superheat and coating on the interfacial heat transfer coefficient in the liquid state, during the solidification, and in the solid state were comparatively discussed. In the liquid state, the interfacial heat transfer coefficient is thought to be affected by the roughness of the mold, the wettability of the casting on the mold surface, and the thermophysical properties of the coating layer. When the solidification begins, the air gap forms between the casting and the mold, and the interfacial heat transfer coefficient becomes a function of the air gap as well as surface roughness and the superheat. In the solid phase, it depends only upon the thermal conductivity and the thickness of the air gap. The coating layer reduces seriously the interfacial heat transfer coefficient in the liquid state and during the solidification.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.12 no.4
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• pp.1565-1574
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• 2011

Scheduling of die casting is a procedure of determining quantities of cast products so as to optimize a predetermined performance criterion. This paper presents a novel scheme of preventing product shortage raised by defective castings when die casting scheduling is applied to real casting operations. The previously developed linear programming (LP) model for die casting scheduling maximizes the average efficiency of melting furnaces in regard of the usage of molten alloy. However, the LP model is not able to cope with the problem of defective products occurring in the casting process. The proposed scheme is that whenever defective products are found in a shift, the foundryman produces additional cast products using the residue of molten alloy left at the end of the next shift. Neither the calculated amount of molten alloy nor the scheduling result of the LP model does not have to be altered for this method. The simulation result demonstrates the superiority and applicability of the newly proposed scheme.

• Journal of Korea Foundry Society
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• v.42 no.4
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• pp.209-217
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• 2022

In the present study, in order to prevent the misrun defects that occur during traditional brass casting, a method for selecting the proper casting process conditions is proposed. A learning model was developed and demonstrated to be able to learn the presence or absence of defects according to the casting process conditions and to predict the occurrence of defects depending on the certain process given. Appropriate process conditions were determined by applying the proposed method, and the determined conditions were verified through a comparison of different simulation results with additional conditions. With this method, it is possible to determine the casting process conditions that will prevent defects in the desired sand model. This technology is expected to contribute to realization of smart traditional brass farming workshops.