• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.2
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• pp.86-92
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• 2021

Usually, the die-cast components used in small mobile devices require finishing processes, such as computer numerically controlled coating. In such cases, porosity is the most important defect. The shape of the molten aluminum that passes through the runner and gate in a mold is the one of the factors that influences gas porosity. To define the spurt index, which numerically indicates the shape of molten aluminum after the gate, Reynolds number and Ohnesorge number are used. Before die fabrication, computer-aided engineering analysis is performed to optimize the filling pattern. Finally, X-ray and surface inspection are performed after casting and machining to evaluate how the spurt index affects porosity and other product parameters. Based on the results obtained herein, a new gating system design process is suggested.

• Korean Chemical Engineering Research
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• v.49 no.1
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• pp.47-55
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• 2011

The optimum mold design and the optimum process condition were constructed upon executing process simulation of rubber injection molding with the commercial CAE program of MOLDFLOW (Ver. 5.2) in order to solve the process-problems of K company relating to cracks, which occurs at the inner cavity wall of C. V. joint boots. As a result it was confirmed that the real cracks occurs at the exactly same position of the cavity as exhibits the defects of weld and meld line and unsatisfactory curing according to the result of simulation. In order to prevent the occurrence of weld and meld line at the defect-position, the location of gate was altered to the optimum position of the cavity. Consequently the filling pattern was established to minimize the degree of the melt-fronts confronting or the melt-flows melding to prevent the occurrence of weld and meld line at the defect-position. It was observed that both gate-positions to maximize the degree of the formation of weld and meld line and air traps are located, respectively, in opposite direction each other with reference to the optimum gate position. In addition, the temperature of mold was raised by $10^{\circ}C$ and maintained at $170^{\circ}C$ for satisfactory curing.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.10
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• pp.115-120
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• 2018

This study examined the cast quality of small-sized induction motor rotors during the die casting process. Numerical analyses with 3-dimensional half models were performed to investigate the filling patterns of aluminum molten metals into a mold after high-speed injections. The following were obtained from numerical analyses and experimental results. First, molten metals started to fill the lower end ring, then moved horizontally to fill the core slot and upper end ring, and finally stopped to fill the rotor core slot. Second, circulation of molten metals occurred at the lower end ring, resulting considerable porosity at the section of lower end ring from the experimental results. Third, further work for obtaining sound quality of rotor core cast is required to develop a new shape of the rotor core cast or improve the die casting conditions.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.7
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• pp.347-352
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• 2019

This study focused on improving the cast quality of small-sized induction motor rotors during the die casting process. A new rotor core cast model was proposed based on previous research results and parametric studies. Numerical analyses using 3-dimensional half models were performed to evaluate the filling patterns of aluminum molten metals into a mold and on-site experiment performed to verify the newly proposed cast model. The following were obtained from numerical filling analyses and experimental results. First, molten metals started to fill the lower end ring, then moved on to fill the core slot and upper end ring and finally stopped to fill at the rotor core slot. Second, significant circulation of molten metals was not observed on the lower end ring, resulting in fewer defects at the section of the lower end ring from the experimental results. Third, the new shape of a rotor core cast was effective in producing rotors with sound cast quality, and reducing the end ring cast defect area by approximately 70 %.

• 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.

• 한국HCI학회:학술대회논문집
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• 2008.02a
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• pp.813-816
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• 2008

In this research we present a method to reconstruct the casting flow simulation result as a 3D model and visualize it on a VR display. First, numerical analysis of heat flow is performed using an existing commercial CAE simulation software. In this process the shape of the original design model is approximated to a regular rectangular grid. The filling ratio and temperature of each voxel are recorded iteratively by predefined number of steps starting from pouring the melted metal into a mold until it is entirely filled. Next we reconstruct the casting by voxels using the simulation result as an input. The color of voxel is determined by mapping the colors to temperature and filling ratio at each step as the flow proceeds. The reconstructed model is visualized on the Projection Table which is one of horizontal-type VR display. It provides active stereoscopic images.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.39 no.10
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• pp.1021-1028
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• 2015

Subminiature lenses are currently widely used in mobile phone cameras and are usually produced by injection molding. The lens molding process has the unique feature of a runner volume that is much larger than the part volume, and this feature should be considered when determining the mold design and molding conditions. In this study, a shell-type runner was proposed as an alternative to the conventional cylindrical runner used for lens molding. An injection molding simulation was performed by applying the proposed shell runner, and the simulation results were compared with those from the cylindrical runner case. It was found that the shell runner could considerably reduce the runner cooling time with only a slight increase in the injection pressure. The effect of the runner thickness was then investigated numerically in terms of the mold filling and cooling characteristics, from which an optimal runner thickness could be determined.

• Composites Research
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• v.15 no.1
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• pp.21-31
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• 2002

To overcome the disadvantages of conventional excavation technology various trenchless (or excavation free, or no-dig) repair-reinforcement technologies have been developed and tried. But trenchless technologies so far developed have some drawbacks such as high cost and inconvenience of operation. In this study, a repairing-reinforcing process for underground pipes with glass fiber fabric polymer composites using VARTM (Vacuum Assisted Resin Transfer Molding) has been developed. The developed process requires shorter operation time and lower cost with smaller and simpler operating equipments than those of the conventional trenchless technologies. For the reliable operation of the developed method, a simple method to apply pressure and vacuum to the reinforcement was devised and flexible mold technology was tried. Also, resin filling and cure status during RTM process were monitored with a commercial dielectrometry cure monitoring system, LACOMCURE. From the investigation, it has been found that the developed repairing-reinforcing technology with appropriate process variables and on-line cure monitoring has many advantages over conventional methods.

• Journal of Korea Foundry Society
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• v.20 no.6
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• pp.400-406
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• 2000

Computer simulation for the predictions of casting defects is very important to produce high quality castings with less cost. Complicate shaped Al solenoid housing part was selected to be cold chamber die cast and a numerical simulation technique was applied for the optimization of the chill vent position and gating. A first design led to insufficient central flow. This flow left the last filled areas falling into the inner portion of the part. And last filled area did not fit the chill vent position. So these resulted in a high possibility of air entrapment in the casting and the design was not proper for the part. The design was improved by using a proper gating system, a more chill vent and proper overflow positions. New design provided a homogenous mold filling pattern and the last filled areas that being located at the overflow and chill vent. Casting plan which produce good quality solenoid housing part was established by using the computer simulation.

• Journal of Powder Materials
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• v.9 no.4
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• pp.267-272
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• 2002

The production of micro components is one of the leading technologies in the fields of information and communiation, medical and biotechnology, and micro sensor and micro actuator system. Microfabrication (micromachining) techniques such as X-ray lithography, electroforming, micromolding and excimer laser ablation are used for the production of micro components out of silicon, polymer and a limited number of pure metals or binary alloys. However, since the first development of microfabrication technologies there have been demands for the cost-effective replication in large scale series as well as the extended range of available material. One such promising process is micro powder injection molding (PIM), which inherits the advantages of the conventional PIM technology, such as low production cost, shape complexity, applicability to many materials, applicability to many materials, and good tolerance. This paper reports on a fundamental investigation of the application of W-Cu powder to micro metal injection molding (MIM), especially in view of achieving a good filling and a safe removal of a micro mold conducted in the experiment. It is absolutely legitimate and meaningful, at the present state of the technique, to continue developing the micro MIM towards production processes for micro components.