• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.314-317
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• 2007

Domestic automobile industries have been focusing their effort on development of exhaust manifolds using high temperature stainless steel. Exhaust manifolds fabricated with stainless steels can be categorized into tubular and cast ones. The former is usually manufactured by forming and welding process and the latter by vacuum casting process. In the present study, high temperature mechanical properties of 5 austenitic stainless steels, one was sand cast and the others vacuum cast, were investigated by performing a series of high temperature tensile tests and high temperature low cycle fatigue tests.

• Journal of the Korean Society of Industry Convergence
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• v.26 no.6_1
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• pp.977-983
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• 2023

The tank uses a twin turbo diesel engine equipped with two turbocharger systems for high output. The main component of the turbocharger system is the turbine housing through which the exhaust flows. Turbine housing is manufactured through a sand casting process, taking into account the shape and material characteristics according to the environmental conditions in which it is used. Currently, turbine housing is imported, and local production is necessary. In this study, basic research was conducted to localize the turbine housing of a tank diesel turbo engine. Reverse engineering and finite element analysis of the imported turbine housing were performed. The prototype of the turbine housing was printed using FDM and PBF 3D printers. The prototype of the turbine housing printed with an FDM 3D printer has an overall appearance similar to 3D modeling, but the printed surface of the whorl part is rough. The prototype printed with the PBF 3D printer is completely identical to the 3D modeling, including the whorl part.

• Design & Manufacturing
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• v.7 no.1
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• pp.45-49
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• 2013

Since the shell-molds are used to make casting the metal parts for the automobile industry, the quality may well be inconsistent with the lower productivity, increasing the cost of the end products. The primary elbow design shell molded steel castings being produced through extrusion process has $180^{\varnothing}$ O.D., $150^{\varnothing}$ I.D., 14mm thickness and 400mm length, while being processed onto the left side of the tubing. The primary cause for the poor processing is the uneven manual shell molding. If the manual shell molds should be produced to have even quality, they would not be processed for tube linking. The purpose of this study was to develop the flask-molds for manufacturing of the shell molds to ensure mass-production, consistent quality, ommission of processing and comfortable working environment. For this purpose, four flask-molds were produced and thereby, four shell molds were assembled. In particular, the shell molds for processing were formed of the fine coated sand to be blown. As a result, productivity increased about three times, while a consistent quality was ensured. Furthermore, the tubes could be linked with each other without being processed, while pallets could be stacked, stored, transported and managed more easily. In a nut-shell, the molding theory could be applied more effectively. However, it is conceived that this study should be followed up by future studies which will research into reliability and endurability of the end products.

• Resources Recycling
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• v.5 no.3
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• pp.24-30
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• 1996

The computcr s~mulatiun model in vanaus s~nelllng process for melling waste cashhg sand was developed by using energy and malcrial balance concept. This modcl can prcdict the coal, flux and oxygen conaumptron and thc volume and temperature of off-gas The ~niljor critical varlablcs for smclting process can be crplained by using the analysis of energy and malc~ialb alance. Thc Innst lmportarlt variables lor smelting process were h i ~ hpo st-combust~anr atla, high heat transfer crficiency and refractory pratcclion lechnalogy. For saving encrg), in this smelting proccss, selection of caw marerials i.e coal, flus was important, cspacially ubi~go f low volatile coal was prufitahle.

• Korean Journal of Heritage: History & Science
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• v.43 no.3
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• pp.102-121
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• 2010

Three bronze bells excavated from the Hoeamsa temple site were investigated for their microstructures and chemical compositions in an effort to understand the technology applied in fabrication, which may represent the related industry established in the early Joseon period. The result shows that the bells were cast from alloys of approximately 85% copper-8% tin-7% lead. The chemical analysis for ten trace elements shows that they were all kept below 0.3 weight %, suggesting that the alloys were made of relatively well-refined copper, tin and lead. The presence of sulfur and iron indicates that chalcopyrite or chalcocite may have been used in the smelting of copper. Evidence has been found that the bells were cast by pouring the liquid metal from the top of the sand molds that were set up in an upright position. No additional treatments, thermal or mechanical, other than a little grinding were applied upon the completion of casting. After the shaping process, a balancing plate was attached to the top of the bell using a steel connection ring. The connection assembly was then fixed to the main body by using molten bronze as a solder. The surface inscription was found carved using different techniques. The differences in the order of strokes and the calligraphic style indicate that the carving was carried out by more than one master. In the absence of documentary evidence on past bronze technology, the present bronze bells with known chronology, provenance and the main agent of production, prove to be a rare and valuable archaeological material for the understanding of the related technology in use in the early Joseon period.

• International Journal of Automotive Technology
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• v.3 no.2
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• pp.47-52
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• 2002

The integration of CAD/CAM/CAE in product development is the key to realize concurrent engineering. Generally, different systems are employed in product development departments. These different systems create a lot of trout)toes such as difficulty in communication, misunderstanding and so on. A new approach to integrate CAD/CAM/CAE in one system based on CATIA thor the end-to-end process in cylinder head development is presented. Hulti Model Technology (MMT) is used to create consistent and associated CAD models for the end-to-end process in cylinder head development. The concept and method to create and organize multi models are discussed. A typical four-layer structure of HHT for mechanical products is defined. The multi level structure of the cylinder head models based on MMT is provided. The CAD models of cylinder head created based on MMT can be used as the consistent model. All models in the downstream of cylinder head development such as structure analysis, CFD, sand core design , casting simulation and so oil are associated with the CAD models. Practice shows the approach in this paper enables the development process to be carried concurrently and can obviously shorten time to the market, reduce product cost and improve product quality.

• Proceedings of the Safety Management and Science Conference
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• 2013.11a
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• pp.587-595
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• 2013

기계가공으로 인한 사고는 작업자에게 치명적인 경우가 많다. 이러한 사고는 완벽한 가공지그을 통해 대부분 예방이 가능하지만 제품설계초기 후가공과 양산 공정은 고려되지 않고 설계되어 기계가공 시 재해로 연결되는 경우가 빈번히 발생하고 있다. 사형주조법은 수작업으로 손쉽게 제품을 생산하는 장점을 가지는 반면 치수오차가 다른 양산공정 보다 크다는 단점을 가진다. 이런 사형 주조품을 기계 가공할 때 제품의 치수편차로 인해 불안전한 고정및 과다한 절삭, 제품이탈, 공구파손, 장비와 공구의 빠른 수명감소 등의 다양한 문제가 발생 하지만 사형주조의 특성상 개선하기 어려운 문제로 인식되고 있다. 본 연구에서는 원형의 용기형태의 제품을 사형주조 후 기계가공 하는 것을 금형으로 대체하기 위한 셸몰드법을 제시하고 셸몰드로 만든 셸주형으로 주조함으로서 표면조도 평균 $Ra9.94{\mu}m$의 기계가공에 준하는 표면을 구현하였다. 외형의 정밀한 제품을 대량 생산하여 가공공정의 간소화 및 평균 두께 편차를 줄임으로서 제품파손 및 제작 시 발생할 수 있는 안전사고예방에 긍정적인 영향을 주었다. 기계가공전 제품의 치수정밀도를 높여 안전성, 생산성향상, 가공 공정단축, 환경개선 등을 이 가능함을 확인하였다.

• Journal of Korea Foundry Society
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• v.24 no.5
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• pp.273-280
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• 2004

Vibrational motions of the compaction table were investigated to select the optimal operation conditions of sand filling and compaction for the EPC process. Their modes were measured at the nine points of the table with changing the relative rotation angles between the two eccentric mass vibrators which were attached parallel beneath the table. Well-defined vibration modes were measured at the center of the table but those of left and right sides of the table were distorted regardless of rotational angle differences. The distortion of vibration modes at both sides of the table were caused by the moment generated by offset positions of two eccentric masses. It was found that the uniform vibration modes would be gathered by controlling the relative distances between the rotating axis and the center of gravity in the compaction system at the various conditions of vibration modes and rotational angle differences.

• 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.

• Korean Journal of Materials Research
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• v.15 no.1
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• pp.14-18
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• 2005

Ni-Cr-Sn-Bi alloys were prepared by air melting and sand casting method and their anti-galling behaviors were examined. Anti-galling properties were dominantly influenced by Bi-rich low temperature precipitates. Alloying effects on the anti-galling properties were investigated for several alloying elements to improve anti-galling properties of the alloy. An alloy with $1-3wt\%$ of Te showed markedly improved anti-galling properties. Metallographic and tribological tests were carried out to find out reasons for excellent properties. It was found that Te containing alloy has finely distributed precipitates of Bi-rich phase. The addition of Te changed the morphology of the Ni-rich primary phase from globular to fine dendritic. As a result, the anti-galling phase precipitated between dendrite arms with fine distribution showed excellent anti-galling properties.