• The Journal of Korean Academy of Prosthodontics
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• v.26 no.1
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• pp.51-61
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• 1988

The recently introduced castable glass ceramics incorporate properties characteristic of natural teeth and they are regarded as an ideal material to restore lost tooth structure. The purpose of this study was to compare the marginal fit of castable ceramic crown with that of the metal-ceramic crown in the process of heat treatment. Two master dies for castable ceramic crowns and metal-ceramic crowns were fabricated from being cast with the base metal. Each master die was duplicated with addition silicone and hard stone. Ten castable ceramic crowns were made on each hard stone die and their marginal openings were measured three times first, after casting; second, after ceramming; third, after shading. The other ten metal-ceramic crowns were made on each hard stone die and their marginal openings were measured three times : first, after casting; second, after degassing; third, after porcelain veneering. Each crown was seated on its master die with the constant force delivered by loading jig. And then, marginal openings were measured on four locations by optical projector at X50 magnification. The results were as follows: 1. The mean marginal openings of castable ceramic crowns were $31.1{\pm}12.7{\mu}m$ after casting; $44.6{\pm}12.8{\mu}m$ after ceramming; $51.2{\pm}16.8{\mu}m$ after shading. 2. The mean marginal openings of the metal-ceramic crowns were $26.2{\pm}13.8{\mu}m$ after casting; $29.8{\pm}10.3{\mu}m$ after degassing; $38.0{\pm}14.5{\mu}m$ after porcelain veneering. 3. There was significant increase in the marginal opening of castable ceramic crowns after ceramming, while metal-ceramic crowns sho(wed significant increase after porcelain veneering (p<0.05). 4. Marginal fit of metal-ceramic crown was better than that of castable ceramic crown (p<0.01).

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.7
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• pp.347-352
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• 2019

This study focused on improving the cast quality of small-sized induction motor rotors during the die casting process. A new rotor core cast model was proposed based on previous research results and parametric studies. Numerical analyses using 3-dimensional half models were performed to evaluate the filling patterns of aluminum molten metals into a mold and on-site experiment performed to verify the newly proposed cast model. The following were obtained from numerical filling analyses and experimental results. First, molten metals started to fill the lower end ring, then moved on to fill the core slot and upper end ring and finally stopped to fill at the rotor core slot. Second, significant circulation of molten metals was not observed on the lower end ring, resulting in fewer defects at the section of the lower end ring from the experimental results. Third, the new shape of a rotor core cast was effective in producing rotors with sound cast quality, and reducing the end ring cast defect area by approximately 70 %.

• Design & Manufacturing
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• v.15 no.2
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• pp.30-35
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• 2021

The casting method uses a mold to solidify a liquid metal to make a solid metal. Since it uses a liquid metal with the least deformation resistance, it has the characteristic that it can easily manufacture even a complex shape. However, the process of solidifying a liquid metal into a solid metal inevitably involves a volume change and contains internal defects such as shrinkage holes. Therefore, in the design of the casting plan, an excess volume called a pressurization compensates for the volume shrinkage. in the product, and it induces the shrinkage hole defects to occur in parts other than the product1). In this study, casting analysis was performed using casting analysis software (anycasting) in order to optimize the design of the tilting gravity casting method for automobile brackets. In particular, the filling and solidification analysis according to the shape and volume of the pressurized metal was conducted, and applied to the actual product to study the effect of the pressurized metal on the shrinkage defect. Through this study, it is possible to understand the effect of the pressure metal on shrinkage defects in the actual product and propose a design of the pressure metal that improves reliability and productivity.

• Transactions of Materials Processing
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• v.23 no.2
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• pp.116-121
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• 2014

Low pressure die casting and flow forming have been successfully used to produce sound road wheels from magnesium alloy AM80. In the current study, high speed compression testing was initially conducted to simulate the flow forming of a Mg wheel. Subsequently the flow forming was simulated with "Forge$^{TM}$", an FEM software package. On the basis of flow forming simulations, the flow forming of the Mg wheel was performed under different conditions. For the flow forming experiments, the preform castings were made by low pressure die casting from AM80, a commercial magnesium alloy. In flow forming of the magnesium preform wheel, the flow forming of the Mg wheel was successfully accomplished when the feed rate was less than half that for the forming of an aluminum road wheel. The reduction in feed rate was 52%. Finally, a comparison with the flow forming simulations was made.

• Transactions of the Korean Society of Automotive Engineers
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• v.20 no.4
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• pp.52-59
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• 2012

The subframe has been generally manufactured by using stamped steel material. Recently, automotive designers are considering aluminum as lightweight material. This paper describes the development process of an aluminum subframe which is made by high level vacuum die casting process, which is beneficial for minimizing gas contents and material properties. The weight of manufactured subframe is reduced by 4kg with the comparison of steel subframe. The aluminum subframe is packaged for the current vehicle layout and the imposed requirement is to attain a better structural performance that is evaluated in terms of mounting stiffness, noise and vibration, and endurance performance. The NVH evaluation results show that sound level is decreased by 8dB with the help of high roll-rod mounting stiffness as well as high structural modes.

• Journal of Electrical Engineering and Technology
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• v.11 no.3
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• pp.639-643
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• 2016

This paper introduces the development process and investigation of a 60kW induction motor for electric vehicles. We present performance improvement in the induction motor of electric vehicle using copper die-casting based on a multi-gate process. Copper die-casting motors can reduce the size of the motor, the loss of the rotor, and material costs. We also introduce electromagnetic, thermal, mechanical design and analysis results that satisfy the design and the performance requirements. In order to analyze losses accurately of induction motor, commercial finite element analysis is done considering PWM voltage and thermal characteristics by using lumped-circuit parameters. Experimental tests are also carried out to validate the traction motor design.

• Korean Journal of Materials Research
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• v.27 no.10
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• pp.544-551
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• 2017

In order to develop a new commercial Al-12%Si casting alloy with improved physical properties, we investigated the effect of adding Sr and TiB to the alloy. Al-12%Si alloys were prepared by die casting at $660^{\circ}C$. The eutectic temperature of the Sr-modified Al-12%Si alloy decreased to $9^{\circ}C$ and the mushy zone region increased. The shape of the Si phase changed from coarse acicula to fine fiber with the addition of Sr. The addition of TiB in the Al-12%Si alloy reduced the size of the primary ${\alpha}$-Al and eutectic Si phases. When Sr and TiB were added together, it worked more effectively in refinement and modification. The density of twins in the Si phase-doped Sr increased and the width of the twins was refined to 5 nm. These results are related to the impurity induced twinning(IIT) growth.

• Journal of Korea Foundry Society
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• v.20 no.2
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• pp.97-103
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• 2000

In this study, a design of experiment, Taguchi method, was applied to optimize gating system design of escalator step die casting parts. Six shape factors which affect filling sequence of melt are adopted and divided into two levels respectively. Initial feeding differences of melt which were calculated by using S/N(signal-to-noise) ratio in each condition were demonstrated with the simulation of Flow-3D software program. Variations of S/N ratio according to shape factors were obtained and the optimal condition of gating system could also be obtained. It could be found that width of gate, contact angle of gate, thickness of runner are more effective factors on the filling sequence of melt than the others in this case of escalator step die casting parts. It showed that the economical gating system and sound filling sequence of melt were obtained by using Taguchi method.

• Korean Journal of Metals and Materials
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• v.50 no.2
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• pp.176-182
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• 2012

The main purpose of this study was to evaluate the endurance against Al alloy melts and wear resistance of an in-situ synthesized titanium matrix composite (TMC) sleeve for aluminum alloy die-casting. The conventional die-casting shot sleeve material was STD61 tool steel. TMCs have great thermal stability, wear and oxidation resistance. The in-situ reaction between Ti and $B_4C$ leads to two kinds of thermodynamically stable reinforcements, such as TiBw and TiCp. To evaluate the feasibility of the application to a TMCs diecasting shot sleeve, the interfacial reaction behavior was examined between Al alloys melts with TMCs and STD61 tool steel. The pin-on-disk type dry sliding wear test was also investigated for TMCs and STD61 tool steel.

• Transactions of Materials Processing
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• v.9 no.5
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• pp.533-538
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• 2000

This study has been carried out to develop a CRT die using hot forging. The conventional CRT die made by casting has defects such as void and inclusion. These defects of the cast die make micro-spots on the surface of the CRT which affect the quality of the final product. So, a hot forging process is developed to avoid these defects of CRT die by the model material test and the rigid-plastic FEM. Firstly, model material tests are carried out with plasticine billets in order to investigate the material flow pattern in the die cavity and to get the reasonable initial values for designing the preform in the FE simulation. And then a finite element analysis has been performed to Predict the preform and the forging load of a CRT die. We also suggest an integrated die-set which combines two die-sets into one die-set to save manufacturing time and cost in case of similar die-size.