• Journal of Korea Foundry Society
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• v.27 no.1
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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.

• Nuclear Engineering and Technology
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• v.54 no.10
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• pp.3909-3918
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• 2022

In the event of a severe accident, the reactor core may melt due to insufficient cooling. the high-temperature core melt will have a strong interaction (FCI) with the coolant, which may lead to steam explosion. Steam explosion would pose a serious threat to the safety of the reactors. Therefore, the study of steam explosion is of great significance to the assessment of severe accidents in nuclear reactors. This research focuses on the development of a two-dimensional steam explosion integrated analysis code called SEINA. Based on the semi-implicit Euler scheme, the three-phase field was considered in this code. Besides, the influence of evaporation drag of melt and the influence of solidified shell during the process of melt droplet fragmentation were also considered. The code was simulated and validated by FARO L-14 and KROTOS KS-2 experiments. The calculation results of SEINA code are in good agreement with the experimental results, and the results show that if the effects of evaporation drag and melt solidification shell are considered, the FCI process can be described more accurately. Therefore, it is proved that SEINA has the potential to be a powerful and effective tool for the analysis of steam explosions in nuclear reactors.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.40 no.1
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• pp.35-40
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• 2017

A most important progress in civilization was the introduction of mass production. One of main methods for mass production is die-casting molds. Due to the high velocity of the liquid metal, aluminum die-casting is so complex where flow momentum is critical matter in the mold filling process. Actually in complex parts, it is almost impossible to calculate the exact mold filling performance with using experimental knowledge. To manufacture the lightweight automobile bodies, aluminum die-castings play a definitive role in the automotive part industry. Due to this condition in the design procedure, the simulation is becoming more important. Simulation can make a casting system optimal and also elevate the casting quality with less experiment. The most advantage of using simulation programs is the time and cost saving of the casting layout design. For a 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 the casting layout design of an automotive Oil Pan_BR2E, Computer Aided Engineering (CAE) simulation was performed with three layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process with three models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflows. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.1
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• pp.162-171
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• 1993

This paper deals with the anisotropy of the mushy region during solidification process of a binary mixture. A theoretical model which specifies a permeability tensor in terms of pricipal values is proposed. Also, the governing equations are modified into convenient forms for the numerical analysis with the existing algorithm. Some test computations are performed for soeidification of aqueous ammonium chloride solution contained in a square cavity. Results show that not only the present model is capable of resolving fundamental characteristics of the tranport phenomena, but also the anisotropy significantly affects the interdendritic flow structure, i.e., double-diffusive convection and macrosegregation patterns.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04a
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• pp.620-625
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• 1995

Finite element analysis tool was developed to analyze the casting process. Generally, casting processes consists of mold filling and solifification. In order to investigate the effects of process variables and to predict the defects, both filling and solidiffication process were simulated simultaneously. At filling process, especiallywe consider thermal coupling to investigate thermal history of material during the filling stage. And thermal condition at the final stage of filling is used as the initial conditions in a solidification process for the exact simulation of the actual casting processes. At mold filling process, Lagrangian-type finite element method with automatic remashing scheme was used to find the material flow. To avoid numerical instability in low viscous fluid, a perturbation method with artificial viscosity is adopted. At solififfication process, enthalpy-based finite element method was used to solve the heat transfer problem with phase change. And elastic stress analysis has been performed to predict the thermal residual stress. Through the FE analysis, solidiffication time, position of solidus line, liquidus line and thermal residual stress are studied. Finite element tools developed in this study will be used process design of casting process and maybe basic structure for total CAE system of castigs which will be constructed afterward.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.26 no.5
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• pp.648-657
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• 2002

This paper presents a numerical analysis on the solidification characteristics in twin-roll strip casting. Unstructured fixed-grid system was employed to deal with phase change. Melting of pure gallium was analyzed to confirm the validity of present program in both structured and unstructured grid systems. An algorithm for simultaneous calculation of the temperature in the roll and the molten metal pool was developed. The flow field in the pool and heat transfer features between pool and roll were shown. The effect of process parameters was also studied. Since the geometry of the molten metal Pool significantly deforms along the casting direction, unstructured grid system is more efficient. The unstructured grid system gives almost the same accuracy, even though the number of grids is only 60% of the structure done.

• International Journal of Air-Conditioning and Refrigeration
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• v.7
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• pp.1-10
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• 1999

In this study, a numerical analysis is made on the ice-formation for laminar water flow inside a stenotic tube. The study takes into account the interaction between the laminar flow and the stenotic port in the circular tube. The purpose of the present numerical investigation is to assess the effect of a stenotic shape on the instantaneous shape of the flow passage during freezing upstream/downstream of the stenotic channel. In the solution strategy, the present study is substantially distinguished from the existing works in that the complete set of governing equations in both the solid and liquid regions are resolved. In a channel flow between parallel plates, the agreement between the of predictions and the available experimental data is very good. Numerical analyses are performed for parametric variations of the position and heights of stenotic shape and flow rate. The results show that the stenotic shape has the great effect on the thickness of the solidification layer inside the tube. As the height of a stenosis grows and the length of a stenosis decreases, the ice layer thickness near the stenotic port is thinner, due to backward flow caused by the sudden expansion of a water tunnel. It is found that the flow passage has a slight uniform taper up to the stenotic channel, at which a sudden expansion is observed. It is also shown that the ice layer becomes more fat in accordance with its Reynolds number.

• Proceedings of the KSME Conference
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• 2001.06e
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• pp.566-569
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• 2001

Researchers have invectigated nasal flow both numerically and experimentally for centuries. Experimental studies most have suffered from various limitations necessary to allow the measurements to be obtained with available equipment. Nasal airflow can be subdivided into two interrelated categories; nasal airflow resistance and heat and mass transfer between the air stream and the walls of the nasal cavity. In this study, thanks to a new method for model casting by a combination of Rapid prototyping and Solidification of clear silicone, a transparent rectangular box containing the complex nasal cavity is made for PIV experiments. The CBC PIV algorithm is used for analysis.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2000.04a
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• pp.195-198
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• 2000

The process of squeeze casting for metal matrix composites (MMCs) has been simulated numerically by using finite difference method. The governing equations to describe fluid flow through porous medium and heat transfer are applied to two dimensional model which is similar to a real system. A computational code has been developed to solve this problem. The influence on infiltration kinetics and solidification time of several parameters is investigated. Cooling curves and temperature distribution with time and position is also shown. The result can be used to design the squeeze casting for MMCs.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.29 no.12 s.243
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• pp.1307-1312
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• 2005

Turbulent in-situ mixing process is a new material process technology to get dispersed phase in nanometer size by controlling reaction of liquid/liquid, liquid/solid and liquid/gas, flow and solidification speed simultaneously. In this study mixing, the key technology to this synthesis method will be studied by computational fluid dynamics. For the simulation of mixing of liquid metal, static mixers will be investigated. Two inlets for different liquid metal meet and merge like 'Y' shape tube. The tube has various shapes such as straight and curved. Also, the radius of curve will be varied. The performance of mixer will be evaluated with quantitative analysis with coefficient of variance of mass fraction. Also, detailed plots of intersection will be presented to understand effect of mixer shape on mixing.