• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.1
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• pp.30-37
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• 2000

In this paper rapid prototyping and precision casting technology have been developed for the manufacturing of inlet gear box of an airplane, Rapid prototyping is a new prototyping technology that produces complicated parts directly from three-dimensional CAD data with a high efficiency and has been extensively applied to various manufacturing processes. In the present work Selective Lase Sintering(SLS) system is utilized in order to manufacture prototype of the inlet gear box. Prototyping technology using SLS is also investigated from the viewpoint of accuracy. Using the SLS master the casting products are manufactured through several processes such as : vacuum casting lost wax shell casting and investment cast-ing. The shrinkage characteristics of wax and cast iron in the casting procedures are considered and then reflected to the design procedure so that the accuracy of the product is improved consequently.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.06a
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• pp.135-147
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• 1997

The production of light metal parts using aluminum is mainly performed by die casting and squeeze casting, which directly fabricate the required shape from the liquid state. However, die casting is subject to defects such as shrinkage porosity and air trapped when molten metal enters the cavity, whilst squeeze casting also has defects due to turbulent flow in the die cavity. Both diecasting and sqeeze casting have inhomogeneous mechanical property in terms of dendritic structure during solidification. Active research has been carried out on semi-solid processing, rather than on conventional process methods such as die casting, which involve various problems. Therefore in this paper, to introduce the fundamental technology for d e design, in die casting and forging process with semi-solid materials, relationship between stress and strain of semi-solid materials, and for producing parts die design has been proposed as parameters of globulization of the microstructure and gate shape. The prevention of various defects to produce sound parts are also introduced.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.11
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• pp.1309-1315
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• 2011

The design process for obtaining the reliable steeraxle casting beam of fork lift truck is studied in this paper, as the casting beam is major component of steeraxle which has a steering function at driving. In this study, the driving mode and damage pattern of casting beam which could be occurred from the customer site were analyzed and it established the design process to predict the fatigue life by FEA(Finite Element Analysis) so that the reliability of steeraxle casting beam could be verified at DVT(Design Validation Test) mode. This paper provides guidance on the process of designing the reliable steeraxle casting beam at the initial design stage and also, provides guidance on the process of solving the problem when the failure is occurred in the field.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.6
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• pp.52-57
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• 1999

Funtional metal prototypes are often required in numerous industrial applications. These components are typically needed in the early stage of a project to determine form, fit and function. Recent R/P(Rapid Prototyping) part are made of soft materials such as plastics, wax, paper, these master models cannot be employed durable test in real harsh working environment. Parts by direct metal rapid tooling method, such as laser sintering, by now are hard to get net shape, pores of the green parts of powder casting method must be infiltrated to get proper strength as tool, and new type of 3D direct tooling system combining fabrication welding arc and cutting process is reported by song etc. But a system which can build directly 3D parts of high performance functional material as metal part would need long period of system development, massive investment and other serious obstacles, such as patent. In this paper, through the rapid tooling process as silicon rubber molding using R/P master model, and fabricate wax pattern in that silicon rubber mold using vacuum casting method, then we tranlsated the wax patterns to numerous metal prototypes by new investment casting process combined conventional investment casting with rapid pototyping & rapid tooling process. with this wax-injection-mold-free investment casting, we developed new investment casting process of fabricating numerous functional metal prototypes from one master model, combined 3-D CAD, R/P and conventional investment casting and tried to expect net shape measuring total dimension shrinkage from R/P part to metal part.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.11
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• pp.62-67
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• 1999

The RP&M(Rapid Prototyping and Manufacturing) is the most appropriate technology for the small-lot production system, in which the production cycle is getting shorter owing to various needs from consumers. Recently RP products which are made of plastics, wax, and paper are used to verify the design of samples. But these products cannot be applied to the real mold because the strength enough to be a mold cannot be given by soft materials such as plastics. So RP products are copied to AFR(Al powder Filled Resin) molds or metal molds, which is called the RP&M. In this paper, RP&M is applied to a casting process. A porous casting mold, which is made from ceramic powder and binder, is used for rapid tooling of aluminum shoes molds.

• Transactions of Materials Processing
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• v.14 no.4 s.76
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• pp.351-359
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• 2005

The semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Also, the rheo-casting has been substituted for thixo-casting, because the rheo-casting can control the solid particles to globular and non-dendritic solid phase. In the rheo-casting process, the important thing is to control the solid particles behavior in semi-solid materials. So in this paper, to control solid particles behavior in semi-solid materials, we experimented about the die filling tests during the semi-solid die casting in 0.3, 0.4, 0.5 and 0, 6 solid fraction. The die filling in semi-solid die casting were simulated by MAGMA soft/thixo module. By the die filling tests and computer simulation, the effect of solid particles behavior in rheology flow had been investigated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.769-773
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• 2002

The die easting process was used to manufacture a motor housing for automobile. Specially automobile parts were required light and high strength. Therefore simulations have been carried out die casting process of motor housing. In this paper, we investigated about characteristics of the die casted motor housing with HPDC(High Pressure Die Casting) process. Also the MAGMAsoft was used as computer simulation code and used material was ADC12(Aluminum Die Casting Alloy). We present the results of filling behavior and solidification process of a motor housing cast. The analysis results obtained about filling behavior and solidification of cast showed good agreement with test results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.664-667
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• 2004

The semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Also, the rheolory casting has been substituted for thixo casting, because the rheology casting can control the solid particles to globular and non-dendritic solid phase. In the rheology casting process, the important thing is to control the solid particles behavior in semi-solid materials. So in this paper, to control solid particles behavior in semi-solid materials, we experimented about the die filling during the semi-solid die casting in 0.3, 0.4, 0.5, 0,6 solid fraction. The die filling in semi-solid die casting were simulated by MAGMAsoft/thixo module. By the die filling tests and computer simulation, the effect of solid particles behavior in rheology flow had been investigated.

• Journal of the Korean Ceramic Society
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• v.42 no.1
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• pp.1-6
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• 2005

In aqueous alumina tape casting, the effects of altering the composition of the suspensions, the binders and the casting thickness were studied. The rheological behavior of the suspensions and the defects of the dried tapes were examined and the relationships between them are discussed. The changes in the defect regions reported in the previous paper were related with the rheological properties with variations of the binder, the composition and the casting thickness. The shear thinning factor increased with the organic content and the solid content (the decrease of water content). The apparent viscosity increased with the shear thinning factor. The relation between the shear thinning factor and the log apparent viscosity was similar for all binder types. In the relation between the defect free region and the rheological properties, the defect free region became narrower with increasing casting thickness. The defect free region is independent of binder type. Therefore, the thicker tape is more difficult to produce in aqueous alumina tape casting. Knowledge of the rheological properties of the suspensions could help Predict the defect type and the possibility of defect free dried tapes.

• Journal of Korea Foundry Society
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• v.20 no.4
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• pp.277-282
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• 2000

The RP&M (Rapid prototyping and Manufacturing) is the most appropriate technology for the small-lot production system, in which the production cycle is getting shorter owing to various needs from consumers. In this paper, RP&M is applied to a casting process. A casting process has a merit of being able to reflect complicated shapes at one time. But it has not been applied to the precision industry because of bad quality on surface. So we will improve characteristics of aluminum casting process using vacuum sealed casting process and porous ceramic mold which is made by slurry casting process.