• 대한기계학회논문집B
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• 제28권11호
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• pp.1348-1358
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• 2004

The filling pattern and an adaptive grid refinement based on the finite element method and Eulerian mesh advancement approach have been developed to analyze incompressible transient viscous flow with free surfaces. The governing equation fur flow analysis is Navier-Stokes equation including inertia and gravity effects. The mixed FE formulation and predictor-corrector method are used effectively for unsteady numerical simulation. The flow front surface and the volume inflow rate are calculated using the filling pattern technique to select an adequate pattern among seven filling patterns at each tetrahedral control volume. By adaptive grid refinement, the new flow field that renders better prediction in flow surface shape is generated and the velocity field at the flow front part is calculated more exactly. In this domain the elements in the surface region are made finer than those in the remaining regions for more efficient computation. The collapse of a water dam and the filling of a fluidity spiral have been analyzed. The numerical results have been in good agreement with the experimental results and the efficiency of the adaptive grid refinement and filling pattern techniques have been verified.

• 한국재료학회지
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• 제16권8호
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• pp.516-523
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• 2006

In recent years, Magnesium (Mg) and its alloys have become a center of special interest in the automobile industry. Due to their high specific mechanical properties, they offer a significant weight saving potential in modern vehicle constructions. Most Mg alloys show very good machinability and processability, and even the most complicated die-casting parts can be easily produced. The die casting process is a fast production method capable of a high degree of automation for which certain Mg alloys are ideally suited. In this study, step-dies and flowability tests for AM50 were performed by die-casting process according to various combination of casting pressure and plunger velocity. We were discussed to velocity effect of forming conditions followed by results of microstructure, FESEM-EDX, hardness and tensile strength. Experimental results represented that the conditions of complete filling measured die-casting pressure 400 bar, 1st plunger velocity 1.0 m/s and 2nd plunger velocity 6.0 m/s. The increasing of 2nd plunger velocity 4.0 to 7.0 m/s decreased average grain size of $\alpha$ phase and pore. It was due to rapid filling of molten metal, increasing of cooling rate and pressure followed by increased 2nd plunger velocity. The pressure should maintain until complete solidification to make castings of good quality, however, the cracks were appeared at pressure 800bar over.

• 한국주조공학회지
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• 제35권2호
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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.

• 한국주조공학회지
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• 제27권1호
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• pp.42-47
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• 2007

Vacuum molding process(V-process) has several benefits such as a lower total production cost and a high quality casting comparing to the conventional sand molding. Influence of the gating design on the molten metal flow was investigated in this study. General criteria for the gating design of the castings and commercial codes for the flow and solidification analysis were used to attain the optimized gating design in V-process. Though mold cavity was filled smoothly under the low initial velocity of molten metal, molten metal dashed against the upper part of the mold before the completion of the mold filling with higher initial molten metal velocity and fell soon. This phenomenon may affect collapsing the mold shape, however it is thought that the possibility of burning out of the vinyl by the molten metal is not so high because vinyl is coated with refractory material.

• Journal of Biosystems Engineering
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• 제33권3호
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• pp.173-178
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• 2008

Some physical properties of rapeseed were measured at five moisture levels of 10.03, 14.91, 20.07, 25.06 and 30.12% (w.b.), which include frictional properties (coefficient of static friction, emptying and filling angle of repose) and aerodynamic properties (terminal velocity and drag coefficient). The physical properties of rapeseed were evaluated as a function of seed moisture content. In the moisture content range, the coefficients of static friction, emptying and filling angle of repose increased linearly with increase of moisture content. The maximum values of coefficients of static friction were on the acrylic surface, varied from 0.34 to 0.43; the next is on the galvanized steel, varied from 0.30 to 0.38; and the minimum were on stainless steel surface, varied from 0.27 to 0.35. Emptying and filling angle of repose varied from 26.12 to 29.62 and 23.83 to 27.05 degrees, respectively. Terminal velocity increased linearly from 3.47 to 3.91 m/s with increase of moisture content. Drag coefficient varied from 1.84 to 1.64 as the moisture content increased. The relationship between drag coefficient and moisture content were expressed by non-linear equation.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 춘계학술대회논문집
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• pp.461-464
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• 2003

A new control volume finite element method is proposed for three dimensional analysis of polymer flow. Tetrahedral finite element is employed and co-located interpolation procedure for pressure and velocity is implemented. Inclusion of pressure gradient term in the velocity shape functions prevents the checkerboard pressure field from being developed. Vectorial nature of pressure gradient is considered in the velocity shape function so that velocity profile in the limit of very small Reynolds number becomes physically meaningful. The proposed method was verified through three dimensional simulation of pipe flow problem for Newtonian and power-law fluid. Calculated pressure and velocity field showed an excellent agreement with analytic solutions for pressure and velocity. Driven-cavity problem, which is reported to yield checkerboard pressure filed when conventional finite element method is applied, could be solved without yielding checkerboard pressure field when the proposed control volume finite element method was applied. The proposed method could be successfully applied to the three dimensional mold filling problem.

• 한국주조공학회지
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• 제27권4호
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• pp.153-158
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• 2007

Molten metal flow in vacuum die casting was characterized by a numerical analysis. The VOF method was used to simulate the filling behaviors of molten metal during filling process. The various vacuum degrees of no vacuum(760 mmHg), 650, 500, 250 and 60mmHg were artificially applied in cavity. And the filling behaviors of molten metal with the applied vacuum conditions were simulated and compared with those of experiment. The results showed that molten metal was partially filled into cavity when vacuum was applied and the filling length of molten metal in cavity was increased with increasing applied reduced pressure in cavity. Also, the simulated filling behaviors of molten metal were apparently similar to those of experiment, indicating the numerical analysis developed in this study was highly effective. Through the result of fluid flow simulation, both relation equations of filling length and filling velocity with the variation of pressure conditions in cavity were calculated respectively and the internal gas contents of casting was significantly reduced by the modification of vacuum gate system.

• 대한기계학회논문집A
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• 제20권3호
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• pp.933-944
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• 1996

In this paper, two new techniques, the pattern filling and the refined flow field regeneration, based on the finite element method and Eulerian mesh advancement approach have been developed to analyze incompressible viscous flow with free surfaces. The gorerning equation for flow analysis is Navier-Stokes equation including inertia and gravity effects. The penalty and Newton-Raphson methods are used effectively for finite element formulation. The flow front surface and the volume inflow rate are calculated using the pattern filling technique to select an adequate pattern among five filling patterns at each quadrilateral control volume. By the refined flow field regeneration technique, the new flow field which renders better prediction in flow surface shape is generated and the velocity field at the flow front part is calculated more exactly. Using the new thchniques to be developed, the dam-breaking problem has been analyzed to predict flow phenomenon of fluid and the predicted front positions versus time have been compared with the reported experimental result.

• 대한기계학회논문집B
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• 제28권4호
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• pp.395-405
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• 2004

The filling pattern and an adaptive grid refinement based on the finite element method and Eulerian mesh advancement approach have been developed to analyze incompressible transient viscous flow with free surfaces. The governing equation for flow analysis is Navier-Stokes equation including inertia and gravity effects. The mixed FE formulation and predictor-corrector method are used effectively for unsteady numerical simulation. The flow front surface and the volume inflow rate are calculated using the filling pattern technique to select an adequate pattern among four filling patterns at each triangular control volume. By adaptive grid refinement, the new flow field that renders better prediction in flow surface shape is generated and the velocity field at the flow front part is calculated more exactly. In this domain the elements in the surface region are made finer than those in the remaining regions for more efficient computation. Using the proposed numerical technique, the collapse of a water dam has been analyzed to predict flow phenomenon of fluid and the predicted front positions with respect to time have been compared with the reported experimental results.

• 한국주조공학회지
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• 제32권2호
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• pp.65-74
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• 2012

In this paper, we present the results of our studies on optimal die design towards development of a vacuum die casting process to fabricate fuel cell bipolar plate with micro-channel array. Cavity and overflow shape is designed by computational filling analysis of MAGMA soft. Optimal die design consists of seven overflows at the end of cavity and three overflows at each side wall of cavity. The molten metal that passed the gate and reached the side wall flowed into the side overflow, no turbulent flow occurred, and the filling behavior and velocity distribution were uniform. In addition, partially solidified molten metal passing through the channel was perfectly eliminated by overflow without back-flow. When vacuum pressure, injection speed of low and high region was 300 mbar, 0.3 m/s and 2.5 m/s respectively with Silafont 36 die casting alloy, sound sample without casting defects was obtained. The experimental results are nearly consistent with simulation results.