• Korean Journal of Metals and Materials
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• v.56 no.11
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• pp.805-812
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• 2018

High pressure die casting is one of the precision casting methods. It is highly productivity and suitable for manufacturing components with complex shapes and accurate dimensions. Recently, there has been increasing demand for efficient heat dissipation components, to control the heat generated by devices, which directly affects the efficiency and life of the product. Die cast aluminum alloys with high thermal conductivity are especially needed for this application. In this study, the influence of elements added to the die cast aluminum alloy on its thermal conductivity was evaluated. The results showed that Mn remarkably deteriorated the thermal conductivity of the aluminum alloy. When Cu content was increased, the tensile strength of cast aluminum alloy increased, showing 1 wt% of Cu ensured the minimum mechanical properties of the cast aluminum. As Si content increased, the flow length of the alloy proportionally increased. The flow length of aluminum alloy containing 2 wt% Si was about 85% of that of the ALDC12 alloy. A heat dissipation component was successfully fabricated using an optimized composition of Al-1 wt%Cu-0.6 wt%Fe-2 wt%Si die casting alloy without surface cracks, which were turned out as intergranular cracking originated from the solidification contraction of the alloy with Si composition lower than 2 wt%.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.279-284
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• 2005

The casting defects that are caused by molten metal were cold shut formation, entrapment of air, gas, and inclusion. But the control of casting defects has been based on the experience of the foundry engineers. In this thesis, the computer simulation analyzed the flow of molten metal. The quantitative analyses which proposed the effective mold design was executed Flow patterns of 0.15-0.16m/s molten metal in 15 mm thin plate casting were investigated in order to optimize die-casting process. As increasing ingate velocity in thin plate casting, cold shot was decreased. The parameters of runner shape that affected on the optimized conditions that was calculated with simple equation were investigated. These die casting process control techniques of automobile valve body mid-plate have achieved good agreement with the experimental data of tensile strength, hardness test, and material structure photographies satisfactory results.

• Design & Manufacturing
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• v.6 no.1
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• pp.18-23
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• 2012

HI-WORTH T-32, a non-powered plasma cutter, is a portable cutter that utilizes compressor-plasma inverter. With a special air-pressure piston, the cutter is semiautomatic. When they were produced by die casting dies, the bodies or housings of the cutter have defects about 100 percent of defect rate due to blisters and thermal deformation. Therefore, they are produced by mechanical machining, which leads to a hike in material and machining costs and to the loss of productivity. And companies are left with insignificant profit margins. Besides mechanical machining, this study proposes to modify defective mold and cut down defective rate and boost productivity.

• Journal of Korea Foundry Society
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• v.32 no.3
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• pp.133-137
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• 2012

Chill vent has a zigzag venting path which allows residual air or gases to exhaust out very quickly from the die cavity. However molten metal sometimes comes out through the gas venting surfaces causing flash. Effect of designing factors of chill vent and processing variables in high pressure die casting on the performance of chill vent was investigated through a series of calculations by using a commercial code. The most influential factor was the thickness of chill vent, followed by inlet velocity, vent width and die temperature.

• Journal of Korea Foundry Society
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• v.31 no.5
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• pp.274-283
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• 2011

The vacuum die casting is a promising candidate of the stamping process for fabrication of fuel cell bipolar plate due to its advantages, such as precision casting, mass production and short production time. This study proposes vacuum die casting process to fabricate bipolar plates in fuel cell. Bipolar plates were fabricated under various injection conditions such as molten metal temperature and injection velocity. Also, according to injection velocity conditions, simulation results of MAGMA soft were compared to the experimental results. In case of melt temperature $650^{\circ}C$, misrun occurred. When the melt temperature was $730^{\circ}C$, mechanical properties were low due to dendrite microstructure. Injection velocity has to set at more than 2.0 m/s to fabricate the sound sample. When melt temperature, injection velocity (Fast shot), and vacuum pressure are $700^{\circ}C$, 2.5 m/s and 30 kPa respectively, sample had good formability and few casting defects. Simulation results are mostly in agreement with experimental results.

• 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.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.5
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• pp.1582-1589
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• 1996

Rapid prototyping is a new prototyping technology which produces three dimensional part models directrly from CAD data and has been extensively applied to various manufacturing processes. There are many types of rapid prototyping systems due to their building principles and materials. In this work, Stereolithography Appaaratus(SLA) which is the most widely-used rapid prototyping system is introduced to achieve die/mold technology innovation. For the purpose, the prototyping technology using SLA is developed such that patterns of which shapes are quite complicated are successfully produced with high accuracy. Using these patterns, prototype die/molds are efficientrly manufactured; a turbocharger rotor, a fan and a wheel patterns, prototype die/molds are efficienterly manufactured ; a turbochager rotor, a fan and a wheel pattern are made, and the molds of the investment casting, the injection molding and the die casting are manufactured respectively. The casting products are produced using these molds and it turns out that these methods are quitre effective for manufacturing products of complicated geometry from the viewpoint of efficiency and productivity.

• Journal of the Korean Society for Heat Treatment
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• v.16 no.5
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• pp.275-280
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• 2003

• Journal of Korean Society of Industrial and Systems Engineering
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• v.35 no.4
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• pp.179-185
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• 2012

When manufacturing die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize casting design of an automobile part (Gear Box) Computer Aided Engineering (CAE) was performed by using the simulation software (Z Cast). The simulation results were analyzed and compared with experimental results. During the mold filling, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system. For making a better production die casting tool, cooling systems on several thick areas are proposed in order to reduce internal porosities caused by the solidification shrinkage.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2005.05a
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• pp.174-179
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• 2005

In the super slow speed die casting process, the casting defects due to melt flow should be controlled in order to obtain sound casting products. The casting defects that are caused by molten metal were cold shut formation, entrapment of air, gas, and inclusion. But the control of casting defects has been based on the experience of the foundry engineers. The calculation of simulation can produce very useful and important results. The calculation data of die casting process condition from the computer simulation by the Z-CAST is made to insure that the liquid metal is injected at the right velocity range and that the filling time is small enough to prevent premature solidification. The parameters of runner shape that affected on the optimized conditions that was calculated with simple equation were investigated. These die casting process control techniques of automobile valve body mid-plate have achieved good agreement with the experimental data of tensile strength, hardness test, and material structure photographies satisfactory results.