• Journal of Korea Foundry Society
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• v.18 no.3
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• pp.246-253
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• 1998

Precision metal mold casting process is a casting method manufacturing mechanical elements with high precision, having heavy/light alloys as casting materials and using permanent mold. To improve dimensional accuracy and the final mechanical properties of the castings, the solidification speed and the cooling rate of the casting should be controlled with the optimum mold cooling system, and moreover, to obtain more accurate control of the whole process interfacial heat transfer characteristic at the mold/casting interface must be studied in advance. In the present study, aluminum alloy casting system with metal mold equipped with electrical heating elements and water cooling system was designed and the temperature histories at points inside the metal mold were measured during the casting process. The heat transfer phenomena at the mold/casting interface was characterized by the heat flux between solidifying casting metal and metal mold, and the heat flux history was obtained using inverse heat conduction method. The effect of mold cooling condition upon the heat flux profile was examined, and the analysis shows that the heat flux value has its maximum at the beginning of the process.

• Design & Manufacturing
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• v.13 no.2
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• pp.49-53
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• 2019

The temperature distribution and lifetime of molds were predicted by computer simulation analysis with various spraying and blowing process of high pressure die casting. After varying the spraying angle and time, the mold temperature, heat exchange and mold life were predicted. As the spraying angle increases, the maximum temperature of the mold decreases, which is because the spraying area increases and the heat exchange with the mold increases. Heat exchange occurs more actively in the blowing process than in the spraying process. This is because the cooling is not performed due to the steam generation. When the spraying angle is 50 degree, the minimum life of the mold is analyzed 200 times. After adjusting the blowing time from 5s to 3s, the minimum lifetime of the mold has been increased almost twice.

• Journal of Korea Foundry Society
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• v.2 no.1
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• pp.2-11
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• 1982

In order to investigate the relationship between the thermal characteristics of the various molds as green sand mold, dry sand mold, $CO_2$ mold and shell mold, and the solidification characteristics of molten metal, the thermal analysis of rarious molds and melt were performed. The structure of Al-Castings was a/so observed. Results obtained in this experiment were as follows : 1) The heating rate of the molds was increased in the order of green sand mold, $CO_2$ mold, dry sand mold and shell mold, On the other hand the solidification time of the melts was shortened in the order of dry sand mold castings, $CO_2$ mold castings, green sand mold castings and shell mold castings. 2) The arrest temperature period in the heating curve of the green sand mold was resulted from the eraporation of moisture contained in mold, which was transfered to the outer side of the mold. 3) The temperature fluctuation of the melt in the shell mold was considered to be resulted from the combution heat of resin contained in the mold. 4) The amounts of heat absorption of the molds were increased in the order of dry sand mold, $CO_2$ mold, green sand mold and shell mold. 5) The higher the solidification rate was, the longer was its shrinkage pipe and the finer its grain size.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.2
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• pp.348-355
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• 1992

Casting structures and properties are determined by the solidification speed in the metal mold. The heat transfer characteristics of the interface between the mold and the casting is one of the major factors that control the solidification speed. According to Sully's research, the thermal resistance exists due to the air-gap formation at the mold-casting interface during the freezing process and the interface heat transfer coefficient is used to describe the degree of it. In this study, one-dimensional Stefan problem with air-gap resistance in the cylindrical geometry is considered and heat transfer characteristics is numerically examined. The temperature distribution and solidification speed are obtained by using the modified variable time step method. And the effects of the major parameters such as mold geometry, thermal conductivity, heat transfer coefficient and initial temperature of casting on the thermal characteristics are investigated.

• Transactions of Materials Processing
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• v.20 no.1
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• pp.29-35
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• 2011

In the design of the injection molding process, various parameters including mold design parameters and molding conditions should be investigated to improve part quality. The mold temperature is one of important processing parameters that affect the flow characteristics, surface appearance, part deformation, mechanical properties, etc. Numerical analyses have been used to predict the temperature distribution of the mold under the given cooling or heating conditions. However, conventional analyses have been performed by assuming that the mold material is a single solid even though a number of plates are assembled to construct an injection mold. In the present study, a numerical approach considering the thermal contact resistance is proposed to provide more reliable prediction of the mold temperature distribution by reflecting the heat-resistance between assembled mold plates.

• Journal of the Korean Society for Heat Treatment
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• v.10 no.3
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• pp.159-164
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• 1997

Non-alloyed and 1.0%Ni alloyed ductile cast iron were cast into the sand mold and metal mold, and finer graphite size was obtained in case of metal mold casting. Direct tempering after casting showed the slight increase of absorbed energy, which is largely due to the relieving of residual stress that is developed during casting. After austempering heat treatment, higher impact energy was obtained in case of metal mold casting than sand mold casting, which is due to the finer graphite size.

• Journal of Korea Foundry Society
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• v.24 no.5
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• pp.281-289
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• 2004

The present study focused on the estimation of the interfacial heat transfer coefficient as a function of the surface temperature of the aluminum casting at the mold/casting interface to investigate the effects of superheat and coating layer. The casting experiments of aluminum into a cylindrical copper mold were systematically conducted to obtain the thermal history during solidification. The thermal history recorded by four thermocouples embedded both in the mold and the casting was used to solve the inverse heat conduction problem using Beck's method. The effects of superheat and coating on the interfacial heat transfer coefficient in the liquid state, during the solidification, and in the solid state were comparatively discussed. In the liquid state, the interfacial heat transfer coefficient is thought to be affected by the roughness of the mold, the wettability of the casting on the mold surface, and the thermophysical properties of the coating layer. When the solidification begins, the air gap forms between the casting and the mold, and the interfacial heat transfer coefficient becomes a function of the air gap as well as surface roughness and the superheat. In the solid phase, it depends only upon the thermal conductivity and the thickness of the air gap. The coating layer reduces seriously the interfacial heat transfer coefficient in the liquid state and during the solidification.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.6
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• pp.1008-1012
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• 2012

Injection molds are fabricated by assembling a number of plates in which mold core and cavity components are inserted. The assembled structure causes a number of contact interfaces between each component where the heat transfer is affected by the thermal contact resistance. However, the mold assembly has been treated as a one body in numerical analyses of injection molding, which has a limitation in predicting the mold temperature distribution during the molding cycle. In this study, a numerical approach that considers the thermal contact effect is proposed to predict the heat transfer characteristics of an injection mold assembly. To find the thermal contact conductance between the mold core and plate, a number of finite element (FE) simulations were performed with the design of experiment (DOE) and statistical analysis. Thus, the heat transfer analyses using the obtained conductance values can provide more reliable results than conventional one-body simulations.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.6
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• pp.146-152
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• 2017

In order to make 3-D glass from 2-D glass for mobile device windows, a mold is used for heat forming. In this process, the temperature of the glass is very important. However, measuring the temperature of the glass inside the mold is very difficult owing to the mold structure and the high temperature. The purpose of this study is to measure the temperature inside the mold by using Process Temperature Control Rings (PTCR) and to compensate for temperature differences in the heat forming machine and inside the mold. The measuring method uses the ceramic material's shrinkage characteristics, which makes it possible to measure the temperature inside the mold at various locations.

• Journal of Korea Foundry Society
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• v.5 no.4
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• pp.283-288
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• 1985

The melt of highly purified Zn was poured by top pouring process into the open green sand mold, that was made by using the 3-plane L-sections pattern. After skin was formed, the unsolified melt was poured out by rolling-over. The thicknesses of skin for each different of castings were investigated with one dimension. The results obtained and could be summerzed as follows: 1) While the 3-plant L-sections castings were solidifying in the mold, solidification blocks of different section modulus in the castings were formed, i.e. 1-dimension divergency block, 2-dimension heat divergency block, 3-dimension heat divergency block, 2-dimension heat convergency block, and 3-dimension heat convergency block. 2) When the chill plate was set up to the mold in order to change section modulus artificially, heat divergency blocks and heat convergency blocks according to the shape of chill plate were revealed.