• Journal of the Korean Society of Visualization
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• v.16 no.1
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• pp.54-60
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• 2018

It is important to develop more efficient and productive casting processes for an automated high precision molten-metal casting system. Detailed analysis of molten-metal flow in the casting process by the numerical approach will help to optimize the control of a ladle. In this study, the smoothed particle hydrodynamics method was applied to analyze casting flow characteristics with different tilting angular speed and initial molten-metal level. The smoothed particle hydrodynamics technique has advantages to easily handle non-linear free surface behavior with the absence of a computational mesh. We found that tilting angular speed has relatively greater effect on the casting flowrate and that the effect of the initial molten-metal level is only minor. Further extensive study will be necessary to find an optimal condition for high efficient casting system.

• Proceedings of the KSME Conference
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• 2007.05b
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• pp.2621-2625
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• 2007

This study aims at analyzing the flow characteristics of the electromagnetic pump using a linear induction motor (LIM) for transferring molten metals. The flow characteristics of the pump are simulated by magnetohydrodynamic(MHD) program. In this system, the LIM is used for transferring molten metal by electromagnetic force. The molten metal is treated as the secondary part of the LIM. Since the LIM produces an electromagnetic force in the duct, the molten metal can flow from the furnace to the reservoir. The flow characteristics of the pump are analyzed using MHD program for magnetic field of 0.1[T] in duct. In order to prove the analysis, we made a prototype electromagnetic pump using LIM.

• 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.

• Journal of Korea Foundry Society
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• v.27 no.4
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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.

• 제어로봇시스템학회:학술대회논문집
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• 1996.10b
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• pp.612-615
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• 1996

In the continuous casting process, molten metal contacts the mold wall and the molten metal surface is subject to the mold oscillation. The mold oscillation results in the oscillation marks on the surface of solidified steel, which has undesirable effects on the quality of slabs. In order to reduce the oscillation marks by achieving soft contact of molten metal with the mold surface, alternating magnetic field is applied to the surface of molten metal. However, if the magnetic field strength becomes too strong, the melt flow induced by the magnetic field. causes the instability of the molten metal surface, which has also the bad influence on the slab quality. Therefore, it is very important to choose the optimal position of the inductor coil and the optimal level of electric power to minimize the surface defects. In the present work, as a first step toward the optimization problem of the process, numerical studies are performed to investigate the effects of coil position and the electric power level on the meniscus shape and the flow field. As numerical tools, the boundary integral equation method(BIEM) is used for the magnetic field analysis and the finite difference method (FDM) with orthogonal grid generation is used for the flow analysis.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.23 no.2
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• pp.226-233
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• 1999

An experimental study has been performed on natural convection heat transfer with a rapid crust formation in the molten metal pool of a low Prandtl number fluid. Two types of steady state tests, a low and high geometric aspect ratio cases in the molten metal pool, were performed. The crust thickness by solidification was measured 88 a function of boundary surface temperatures. The experimental results on the relationship between the Nusselt number and Rayleigh number In the molten metal pool with a crust formation were compared with existing correlations. The experimental study has shown that the bottom surface temperature of the molten metal layer, in all experiments. is the major influential parameter in the crust formation, duo to the natural convection flow. The Nusselt number of the case without a crust formation in the molten metal pool is greater than that of the case with the crust formation at the same Rayleigh number. The present experimental results on the relationship between the Nusselt number and Rayleigh number In the molten metal pool match well with Globe and Dropkin's correlation. From the experimental results, a now correlation between the Nusslet number and Rayleigh number in the molten metal pool with the crust formation was developed as $Nu=0.0923(Ra)^{0.302}$ ($2{\times}10^4< Ra<2{\times}10^7$).

• Proceedings of the KSME Conference
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• 2003.04a
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• pp.2139-2144
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• 2003

In steel-making processes of iron and steel industry, the purity and quality of steel can be dependent on the amount of CO contained in the molten metal. Recently, the supersonic oxygen jet is being applied to the molten metal in the electric furnace and thus reduces the CO amount through the chemical reactions between the oxygen jet and molten metal, leading to a better quality of steel. In this application, the supersonic oxygen jet is limited in the distance over which the supersonic velocity is maintained. In order to get longer supersonic jet propagation into the molten metal, a supersonic coherent jet is suggested as one of the alternatives which are applicable to the electric furnace system. It has a flame around the conventional supersonic jet and thus the entrainment effect of the surrounding gas into the supersonic jet is reduced, leading to a longer propagation of the supersonic jet. The objective of the present study is to investigate the supersonic coherent jet flow. A computational study is carried out to solve the compressible, axisymmetric Navier-Stokes equations. The computational results of the supersonic coherent jet are compared with the conventional supersonic jet.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.4
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• pp.148-155
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• 1998

It is commonly known that, in GMAW, the characteristics of metal transfer and the size of molten drop are highly dependent on the welding current. These changes in the characteristics of metal transfer has a considerable effect on the weld quality, and a lot of studies have been made on metal transfer modes for that reason. In this study, two cases were investigated; the one in which the metal transfer proceeds with gravitational force, surface tension, and no electromagnetic force, and the other in which the process has electromagnetic term in addition, where the current density in the fluid has been assumed to have Gaussian distribution on any given cross-section and it acts vertically. Using fluid flow analysis, this study has observed the whole process of the development and break-up of the molten drop, and it also showed that transitional processes, drop rate, and the drop size in each metal transfer mode can be estimated.

• Journal of Korea Foundry Society
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• v.31 no.3
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• pp.124-129
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• 2011

We applied two numerical schemes to improve accuracy of the solution in the flow simulation of molten metal. One method is Piecewise Linear Interface Calculation (PLIC) method and the other is Donor-Acceptor (D-A) method. In the present work, we have tested simple problems to verify the module of the interface reconstruction algorithms. After validations, accuracy and efficiency of these two methods have compared by simulating various real products. On the numerical simulation of free surface flow, it is possible for PLIC method to track very accurately the interface between phases. PLIC method, however, has the weak point where a lot of computational time hangs, though it shows the more accurate interface reconstruction. Donor-Acceptor method has enough effectiveness in the macro observation of mold filling sequence though it shows the inferior accuracy.

• Transactions of Materials Processing
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• v.14 no.3 s.75
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• pp.224-232
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• 2005

The high-pressure die-casting is one of the most effective methods to produce a large amount of products in short cycle time. This process, however, has a problem that the gas porosity defect appears easily. The generation of gas porosity is known mainly due to the air entrapment during the injection stage. Most of numerical simulations for the molten metal flow pattern observations have done in the treating of one phase fluid flow but the gas-liquid interface is essentially multi- phase phenomenon. In this paper, the two-phase fluid flow numerical simulation methods have been adapted to predict the gas porosity generations in the molten metal. The accuracy and the usefulness of the new simulation module have been emphasized and verified through some comparison experiments.