• Journal of Korea Foundry Society
• /
• v.18 no.5
• /
• pp.450-461
• /
• 1998

The optimal reheating conditions to apply the thixoforging and semi-solid die casting process were investigated by changing the reheating time, the holding time, the reheating temperatures, the capacity of the induction heating system, and the adiabatic material size. In the case of solid fraction fs=50% (for semi-solid die casting), the microstructure of SSM (specimen size:$d76{\times}l90$) at the condition of the first elevating time of 4 min, holding time of 1 min and holding temperature of $350^{\circ}C$, the second elevating time of 3 min, holding time of 3 min and holding temperature of $575^{\circ}C$, the third elevating time of 1 min, holding time of 2 min and holding temperature of $584^{\circ}C$, capacity of Q=8.398KW is obtained with globular microstructure and finest. In addition, in the case of solid fraction fs=55% (for thixoforging), the SSM (specimen size:$d76{\times}l90$) at the condition of the first elevating time of 4 min, holding time of 1 min and holding temperature of $350^{\circ}C$, the second elevating time of 3 min, holding time of 3 min and holding temperature of $570^{\circ}C$, the third elevating time of 1 min, holding time of 2 min and holding temperature of $576^{\circ}C$, capacity of Q=12.04KW is obtained with the finest globular microstructure. We saw that the most important factor in a three-step reheating process is the final holding time.

• Journal of Korea Foundry Society
• /
• v.26 no.5
• /
• pp.211-216
• /
• 2006

The study for thixoextrusion process of 7075, 7003 Al wrought alloys and AZ31 Mg wrought alloy was carried out with respect to reheating rate, isothermal holding temperature and time with an emphasis to the effect of homogenization on thixotropic micro-structures during the partial remelting, especially in the low liquid fraction ($f_L<0.2$). The liquid fraction and average grain size with respect to reheating profile such as reheating rate, isothermal holding temperature and time were almost uniform. It is considered very useful for thixoextrusion in terms of process control such as billet temperature control and actual extrusion time. Micro-structural controls of 7075, 7003 Al wrought alloys and AZ31 Mg wrought alloy before and after homogenization were available and thixotropic microstructures were obtained in both specimens.

• Transactions of the Korean Society of Mechanical Engineers B
• /
• v.24 no.11
• /
• pp.1549-1554
• /
• 2000

A new method to determine the total heat exchange factor was proposed for the prediction of billet temperature in a reheating furnace. This method employed the squared of the difference between measured and predicted temperatures as an objective function. The real billet temperature in a walking beam type reheating furnace with 19.75m of its effective length was directly measured by thermocouples. The present method was validated by showing that the predicted billet temperature was in a good agreement with the measured one.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1999.03b
• /
• pp.199-202
• /
• 1999

Many processing times for fabricating complex shaped parts by near net shape process such as thixoforming or semi-solid forming, are required due to the time for die design, induction heating and forming process. Therefore, for the thixoforming process, multi-capacity induction heating process is very important due to the reduction of the processing time and cost. It is indispensable to adopt a power-time heating pattern which manages to conciliate complete eutectic melting at the core with limited overheating at the periphery. The total reheating time is thus dependent on billet diameter; in inches$(pm20%)$. Typically, high frequency is used for the rapid reheating of the billet to the eutectic temperature range and low frequency for the remelting of the desired fraction of liquid and for the radial homogeneization of the liquid fraction. So in this study, the multi-capacity induction heating conditions of ALTHIX 86s alloy to reduce the processing time and cost would be proposed. The suitability of multi-capacity induction heating conditions would be verified through the comparison to Garat's data.

• Journal of the Korean Ceramic Society
• /
• v.11 no.2
• /
• pp.3-10
• /
• 1974

For the manufacture of the silver-yellow glass, silver nitrate was used as a colorant in the base glass of $K_2O$-CaO-$SiO_2$ system. The latter in which the optimum condition was revealed showing beautiful yellow color had been selected among others after the preparatory studies to choose base glass. Other base glass systems considered were $Na_2O$-CaO-$SiO_2$, $R_2O$-PbO-$SiO_2$ and $R_2O$-PbO-BaO-$SiO_2$. The color developed on the specimen in various conditions was examined, using spectorphotometer, in term of the changes in absorbance with wavelength in the visible range. Experimental variables were the amount of the colorant and the additives, reheating temperature and time. The additives such as ZnO, BaO, $B_2O_3$ and $As_2O_3$ were added to increase the coloring action. It was observed that as the amount of silver increased in the base glass the absorbance around $410{\mu}m$ showed the increasing tendency, but the width of absorption curve was wider. Hence, the optimum amount of silver appeared to be 0.11~0.12%. It was found that ZnO was effective additive when present about 0.1%, while $As_2O_3$ ineffective rather retarding the coloration. Borax and $BaCO_3$ were proved effective when contained separately, but appeared ineffective when coexisted. Proper reheating temperature and time was ranged 550~$580^{\circ}C$ and 50~60 minutes. The higher the reheating temperature and the longer the reheating time, the absorbance was increased, while the width of absorption curve was wider. The colored glass prepared in the present experimental condition was found to have good water-resistance for the decorative purpose.

• International Journal of Fuzzy Logic and Intelligent Systems
• /
• v.7 no.3
• /
• pp.182-187
• /
• 2007

A fuzzy modeling method is proposed to build the dynamic model of a walking-beam reheating furnace from the recorded data. In the proposed method, the number of membership function on each variable is increased individually and the modeling accuracy is evaluated iteratively. When the modeling accuracy is satisfied, the membership functions on each variable are fixed and the structure of fuzzy model is determined. Because the training data is limited, in this process, as the number of membership function increase, it is highly possible that some rules are missing, i.e., no data in the training set corresponds to the consequent part of a missing rule. To complete the rulebase, the output of the model constructed at the previous step is used to generate the consequent part of the missing rules. Finally, in the real time application, a rolling update scheme to rulebase is introduced to compensate the change of system dynamics and fine tune the rulebase. The proposed method is verified by the application to the modeling of a reheating furnace.

• International Journal of Control, Automation, and Systems
• /
• v.5 no.1
• /
• pp.43-50
• /
• 2007

Reheating furnace is an essential facility of a rod mill plant where a billet is heated to the required rolling temperature so that it can be milled to produce wire. Although it is very important to obtain information on billet temperatures, it is not feasible during furnace operation. Consequently, a billet temperature profile should be estimated. Moreover, this estimation should be done within an appropriate time interval for an on-line application. In this paper, a billet heat transfer model based on 2D FEM(Finite Element Method) with spatially distributed emission factors is proposed for an on-line billet temperature estimation and also a measurement is carried out for two extremely different furnace operation patterns. Finally, the difference between the model outputs and the measurements is minimized by using a new optimization algorithm named uDEAS(Univariate Dynamic Encoding Algorithm for Searches) with multi-step tuning strategy. The obtained emission factors are applied to a simulation for the data which are not used in the model tuning for validation.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2000.11a
• /
• pp.902-905
• /
• 2000

As the manufacturing processes of automotive engine piston, gravity die-casting, squeeze casting, hot forging and powder forging process are generally used for the various specifications. As the semi-solid forming(SSF) is compared with conventional casting such as gravity die-casting and squeeze casting for the characteristics of its process, the product without inner defects such as gas porosity and segregation can be obtained and its microstructure is globular grain. In SSF process, the materials are heated up to the temperature between the solvus and liquidus line at which the materials exists in the form of liquid-solid mixture. In this time, Discussion is given about reheating process of row material and results are presented regarding accurate temperature and process variables controlling for right solid fractions.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1997.06a
• /
• pp.183-195
• /
• 1997

The micorstructural characteristics, particularly $\alpha$-halo formation, in semi-solid state processed hypereutectic Al-Si alloy was investigated. The microstructural changes during reheating of wedge type mold cast ingot, hot-rolled sheet, and Si particulate reinforced Al composite was compared with those occurred during stirring of semi-solid state hypereutectic alloy. In the case of semi-solid state reheating of wedge type ingot and hot-rolled sheet, fine particles of Si as well as $\alpha$-halo formed after heat treatment. Although there seemed to be no coarsening with variations of holding time, the region of $\alpha$-halo decreased due to homogenization. Nucleation and recrystallization was accelerated with the addition of alloying elements during hot rolling resulting in primary Si particle size decrease and $\alpha$-halo formation. In the case of extruded specimens, very little morphological change of reinforcing Si particles was observed. Almost no $\alpha$-halo formed during reheating because of the oxide film formed on the reinforcing Si particles which acted as a diffusion barrier between the matrix and the primary Si particles.

• Transactions of the Korean Society of Mechanical Engineers B
• /
• v.25 no.8
• /
• pp.1030-1036
• /
• 2001

A new mathematical model to determine the optimal gas temperatures in reheating furnace was proposed for the good quality of products. This model employs sensitivity method to calculate the optimal gas temperatures in each zone for heating the slab up to its discharging target temperature and for heating it uniformly. This method was validated by showing that the calculated discharging temperature of the slab was in a good agreement with its prescribed discharging target one through an off-line simulation.