• Journal of Korean Society of Industrial and Systems Engineering
• /
• v.36 no.4
• /
• pp.71-76
• /
• 2013

For a die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize the casting layout design of an automotive Oil Pan_DX2E, Computer Aided Engineering (CAE) simulation was performed with two layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process with two models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflow. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2002.04a
• /
• pp.3-7
• /
• 2002

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

• Journal of the Korean Society for Precision Engineering
• /
• v.15 no.12
• /
• pp.62-67
• /
• 1998

An experimental study has been carried out to investigate casting process parameters which influence on the microstructures of cast preforms in casting/forging process of aluminum alloy. In the casting process, pouring temperature, pouring time, mold temperature, mold material, and, cooling method are selected as process parameters. With the cast preform, a forging test has been performed to compare mechanical properties of final products between casting/forging process and forging process. From the experimental results, low mold temperature and water cooling method are favorable for obtaining minute microstructures of cast preforms. Casting defects included in cast preforms. such as pores and shrinkage cavity, are eliminated by the forging process. And comparing cast/forged products with conventionally forged products, the former are almost as same as the latter in mechanical characteristics.

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

• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• v.26 no.4
• /
• pp.357-364
• /
• 2017

Metal casting is a process in which molten metal or liquid metal is poured into a mold made of sand, metal, or ceramic. The mold contains a cavity of the desired shape to form geometrically complex parts. The casting process is used to create complex shapes that are difficult to make using conventional manufacturing practices. For the optimal casting process design of sleeve parts, various analyses were performed in this study using commercial finite element analysis software. The simulation was focused on the behaviors of molten metal during the mold filling and solidification stages for the precision and sand casting products. This study developed high-life sleeve parts for the sink roll of continuous hot-dip galvanizing equipment by applying a wear-resistant alloy casting process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1999.03b
• /
• pp.102-106
• /
• 1999

One of the main causes of unwanted dimensional changes in precision metal mold casting parts is excessive and irregular residual stresses induced by temperature gradients and plastic deformation in the solidifying shell. Residual stresses can also cause stress cracking and lower the fatigue life and fracture strength of the casting parts,. In the present study aluminum alloy casting system with metal mold equipped with electrical heating elements and water cooling units was designed and the casting specimens were produced to quantify the effects of different cooling conditions on the development of residual stresses. the layer removal method was used to measure the biaxial residual stresses in casting specimens produced from the experiments. The experimental results agreed with Tien-Richmond's theoretical model for thermal stress development for the solidifying metal plate

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

• Transactions of Materials Processing
• /
• v.9 no.4
• /
• pp.413-420
• /
• 2000

In the die casting process, the flow of liquid metal has significant influence on the quality of casting products and die life. For the optimal process design of front housing part of aircon compressor, various analyses were performed in this study by using computer simulation code, MAGMAsoft. The simulation has been focused on the molten metal behaviors during the filling and solidification stages for the sound casting products. Two cases of casting design that have different types of gating system are considered in the analysis. The potential sites where the casting defects may occur is examined by computer simulation and an improved design process is proposed. Also the effect of partial squeeze on the quality of casting products is considered and the optimal time lag after filling process is determined. For the die-stability, the effect of operational parameters such as die temperature, heat cycle and spot cooling on the die life has also been analyzed.

• Transactions of Materials Processing
• /
• v.8 no.5
• /
• pp.491-497
• /
• 1999

The effect of partial squeeze on the quality of casting products in the vacuum die casting was investigated to make defect free casting products with excellent mechanical properties. The partial squeeze and vacuum die casting process was industrially implemented in making reaction shaft support which was made of a hypereutectic Al-15%Si alloy. To combine squeezing and vacuum effects, the plunger injection system was designed and attached on the chill vent type vacuum machinery system. The combination of vacuum effect before injection and partial squeezing effect after injection resulted in defect free die casting products. The uniform distribution of fine eutectic and proeutectic Si obtained from trial process also provided excellent mechanical properties.

• Journal of Korea Foundry Society
• /
• v.20 no.2
• /
• pp.80-88
• /
• 2000

Continuous casting equipment was designed to cast the metallic uranium rods, and a thermal analysis was carried out to calculate the temperature and solidification profiles. Fluid flow and heat transfer analysis model including the effects of phase change was used to simulate the continuous casting process by finite volume method. In the design of continuous casting equipment, the casting speed, pouring temperature and cooling conditions should be considered as significant factors. In this study, the effects of casting speed, pouring temperature, and air gap between the uranium and mold were investigate. The results represented that the temperature and solidification profiles of continuous casting equipment varied with the casting speed, pouring temperature, and air gap.