• Journal of Korea Foundry Society
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• v.36 no.6
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• pp.208-214
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• 2016

Casting defects, which are closely related to entrapped air bubbles and metallic oxides, occur very frequently in the casting process. Many researchers have shown that these defects can be reduced by adopting an appropriate gating system design. But, it is difficult for field engineers to identify a specific gating system that is more appropriate for their products. In this study, we tried to draw a comparison of gating system designs with and without ceramic foam filters. A ceramic foam filter was added to the horizontal runner just after the sprue to prevent air bubble generation and to reduce turbulence without change of the gating system design. To verify the effects of initial pouring velocity, the experiment was conducted with four different amounts of water volume in the reservoir. Results of the water modeling experiment applying the filter showed remarkably changed flow characteristics. Although the study confirmed that use of the filter may change the flow characteristics, it needs to be noted that only filter use alone cannot solve all the problems caused by a poorly designed gating system.

• International Journal of Precision Engineering and Manufacturing
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• v.4 no.2
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• pp.39-48
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• 2003

In the Semi-Solid Diecasters design, a Seni-Solid Diecasters experiment has usually been carried out before producing new casts. At the Semi-Solid Diecasting stages, the runner-gate part has been always repeatedly corrected, which leads to a tedious processing time and high processing cost. Much experience is essential in manual assessment and if the design is defective, much time and a great deal of efforts will be wasted in the modification of the die. In this study, a design system has been developed based on the design database In addition, a gate experiment for the gating system design has been tarried out to append the database. It is possible for engineers to make efficient gating system design of Semi-Solid Diecasting and it will result in the reduction of expenses and time to be required.

• Journal of the Korean Society of Industry Convergence
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• v.25 no.5
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• pp.889-898
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• 2022

In this study, sand casting process was applied to manufacture a large aluminum turbo-type fan used for tank powerpack. To apply the sand casting method, the turbo fan was reverse engineered, and after designing three gating systems, the optimal gating system design was selected by performing casting simulation. In the case of the bottom up-gating system, there is a significant temperature loss of the molten alloy during blade filling. When the molten alloy is completely filled into the sand mold, the blade upper tip and front shroud are below the liquidus temperature. In the case of the top down-gating system, molten alloy scattering occurs, but the temperature loss while the blade is filled is smaller than that of the bottom up type. And after the inflow of molten alloy into the mold is completed, the blade upper tip and front shroud are higher than the liquidus temperature. A sand mold was manufactured with the top down-gating system and the casting process was performed. The fan was made perfectly in appearance without any unfilled parts.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.324-328
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• 2002

Semi-Solid Diecasters usually carry out the Semi-Solid diecasting experiments before producing new casts. At the Semi-Solid diecasting stages, the runner-gate part has been always repeatedly corrected, which leads to a tedious processing time and increased processing cost. A large amount of experience is essential in manual assessment and if the design is defective, much time and a great deal of efforts will be wasted in the modification of the die. In this study, design system has been developed based on design database. In addition, gate experiment for gating system design has been carried out to append the database. It is possible for engineers to make efficient gating system design of Semi-Solid diecasting and it will result in the reduction of expenses and time to be required. The detailed contents of the research are described in the followings. An attempt is made to link programs incorporating a number of expert design rules with the process variables obtained by commercial FVM softwares, MAGMAsoft, to form a useful package.

• Journal of Biomedical Engineering Research
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• v.28 no.1
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• pp.132-138
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• 2007

MR(magnetic resonance) image of moving organ such as heart shows serious distortion of MR image due to motion itself. To eliminate motion artifacts, MRI(magnetic resonance imaging) scan sequences requires a trigger pulse like ECG(electro-cardiography) R-wave. ECG-gating using cardiac cycle synchronizes the MRI sequence acquisition to the R-wave in order to eliminate image motion artifacts. In this paper, we designed ECG/PPG(photo-plethysmography) gating system which is for eliminating motion artifacts due to moving organ. This system uses nonmagnetic carbon electrodes, lead wire and shield case for minimizing RF(radio-frequency) pulse and gradient effect. Also, we developed a ECG circuit for preventing saturation by magnetic field and a finger plethysmography sensor using optic fiber. And then, gating pulse is generated by adaptive filtering based on NLMS(normalized least mean square) algorithm. To evaluate the developed system, we measured and compared MR imaging of heart and neck with and without ECG/PPG gating system. As a result, we could get a clean image to be used in clinically. In conclusion, the designed ECG/PPG gating system could be useful method when we get MR imaging of moving organ like a heart.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.8
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• pp.116-125
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• 2002

Semi-Solid Diecasters usually carry out the Semi-Solid diecasting experiments before producing new casts. At the Semi-Solid diecasting stages, the runner-gate part has been always repeatedly corrected, which leads to a tedious processing time and increased processing cost. A large amount of experience is essential in manual assessment and if the design is defective, much time and a great deal of efforts will be wasted in the modification of the die. In this study, design system has been developed based on design database. In addition, gate experiment for gating system design has been carried out to append the database. It is possible for engineers to make efficient gating system design of Semi-Solid diecasting and it will result in the reduction of expenses and time to be required. The detailed contents of the research are described in the followings.

• Journal of the Korean Society of Industry Convergence
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• v.26 no.5
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• pp.945-952
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• 2023

In this study, the sand casting process was applied to design the gating system and perform casting simulation in order to domestically produce the submarine mast cover. Based on simulation results, casting experiments were conducted to produce a soundness prototype. The design concept of the mast cover's gating system was based on the design of bell casting. By arranging eight tower-type gates in a circle at 45° intervals, the flow of melt flowing into each gate was uniform and did not mix with each other, and the velocity of melt was also uniform. The mast cover made of Ni-Al-Bronze alloy has no unfilled parts. However, small porosities and flow marks occurred on the surface in several places. Yield strength and ultimate tensile strength are 279.3 MPa and 675.7 MPa, respectively, and elongation is 21.2%.

• 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.298-301
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• 2009

In this study, the casting process using forged insert was investigated to characterize the manufacturing process by which good mechanical properties can be obtained when compared with existing casting products. Process analysis for the casting design was performed by using FVM (Finite Volume Method) software. In filling process, three kinds of candidate gating systems are considered and analyzed respectively. The molten metal behavior in gating system is so important that it affects the solidification behavior of the cast.

• Journal of Korea Foundry Society
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• v.37 no.3
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• pp.71-77
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• 2017

Casting defects produced during the casting process seriously affect the mechanical properties of the resulting products, reduce the performance capabilities of the product, and also result in economic losses. Therefore, this paper mainly investigates the causes of defects and methods by which to reduce these defects stemming from molten metal flows in a runner system of the type widely used in the sand mold casting process. The flow characteristics of a molten alloy are difficult to observe during the actual casting process. For this reason, a water model was used to observe the flow in the casting process, and the flow in each case was recorded using high-speed cameras as part of the experimental process of this study. Several repetitive experiments were performed to improve the accuracy of the experimental results. The traditional casting system was modified according to the design rules proposed by Campbell, and the system was termed flow-adaptive gating system with a water model. Comparing the flow characteristics of traditional and adaptive gating systems with a water model shows that the bubbles in the water in the latter case are reduced more significantly than in the former case. A ceramic filter system was adapted to the flow-adaptive gating system to minimize the instability of the flow during filling, which occurs as the fluid velocity in the runner increases. In additional, the flow behavior with and without the filter system were compared. The water model system in this work was shown to be able to verify that the adaptation of the filter system brings improvements by stabilizing the flow and reducing the amount of bubbles in the runner system. Moreover, using the flow-adaptive runner system with the filter system leads to considerably stable flows in the runner system.