• Journal of Korea Foundry Society
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• v.43 no.1
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• pp.31-36
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• 2023

• Journal of Korea Foundry Society
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• v.22 no.3
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• pp.137-143
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• 2002

Silica sand, zircon sand, and steel shots were used as mold packing materials in lost foam casting of the aluminum alloy bar. Vibration acceleration in three directions and temperatures in the casting and mold were measured, and packing and cooling characteristics of these materials were investigated. Packing densities increased with increase in vibration magnitude and time, and were $1.41{\sim}1.49g/cm^2$ for silica sand, $2.54{\sim}2.86g/cm^2$ for zircon sand, and $3.92{\sim}4.52g/cm^2$ for steel shots. Sound castings were obtained only without evacuation of the flask during pouring. Solidification time became faster in order of silica sand, zircon sand and steel shot packing because steel shot has the highest cooling capacity of them. Solidification time of steel shot packing was shortened to about 1/2 of silica sand packing. Cooling capacity of sand mold was generally evaluated by heat diffusivity of the mold, however could be simply evaluated with specific heat per unit volume of the packing material in lost foam casting.

• Korean Chemical Engineering Research
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• v.44 no.2
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• pp.136-148
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• 2006

A foundry makes various machinery parts made by iron. For manufacturing machinery parts, they usually uses wooden mold with molding sand and pour the molten iron into wooden mold through inlet. A foundry have many processes including Furan process, In Furan process workers prepares a wooden mold in the molding sand. So they fixes wooden mold in sand housing and then they fill the molding sand in the sand housing. Molding sand should be sticky enough to sustain the shape of wooden mold, so several materials are needed to prepare the suitable molding sand. The first step of Furan process is making the molding sand with molding sand and Voltaic Organic Compounds (VOC) and the second step of Furan process is pour the molding sand into the wooden molding housing. This two step of process generated noxious VOC and various size of dust. So the process is very dirty and dangerous one. Because of these, Workers frequently shrink out of the plant. The company related with foundry usually faced on the difficult situation for engagement and always have shortage of hiring problem. Through this study, we developed a system which removes toxic VOC and dust simultaneously. We design and construct real system and install it at real plant. Before setting up this system, the working surroundings VOC (for formaldehyde) 15 ppm and Dust(for $PM_{10}$) $8,000{\mu}g/m^3$. After setting up this system, working surroundings is improved by VOC (for formaldehyde) 0 ppm, Dust(for $PM_{10}$) $4{\mu}g/m^3$, and the work evasion factor is removed. So we contribute to solve hiring problem of this company and increasing the productivity also.

• Journal of Korea Foundry Society
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• v.1 no.3
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• pp.19-29
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• 1981

An emphasis has been placed on the importance of selecting a sand for furan sand process, which ie affected by the properties of sand. Investigations have been carried out to use the domestic artificial sands for the furan sand process. For laboratory investigations, the sands have been prepared and tested for chemical analysis, loss on ignition, sieve analysis, AFS grain fineness number, grain shape, PH value, acid demand, surface shape, theoretical surface area, moisture absorption, crushing durability and compressive strength and S. S. I. of molding sands. Most commercial sands have been found to be able to be used. The main requirement of the sands has been shown to be that 3 or 4 screen sands, AFS no.40-70 (or 100), of low acid demand, good surface area and good grain shape require less resin and catalyst to give an adequate strength.

• Journal of Korea Foundry Society
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• v.4 no.1
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• pp.12-20
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• 1984

In order to investigate the effect of size of sand grains, bentonite content and moisture on mixing power, standard mixing power, permeability, green compressive strength and green mold hardness were measured with mixing time, and also coated layer of mixed sand with time was observed by optical microscope and scanning electron microscope. From this experiment, the results were summarized as follows. 1. Mixing power increased as size of sand grains decreased. 2. Mixing power increased gradually as bentonite content increased and in particular, increased rapidly in 7-10% bentonite. 3. Mixing power increased as moisture content decreased. 4. The mixing time required to get the optimum mixing power decreased as moisture content and grain size increased, but increased as bentonite content increased.

• Journal of Korea Foundry Society
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• v.4 no.2
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• pp.102-107
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• 1984

The variations of the mold compression strength were studied by varing the contents of the silicon powder and water glass, silion purities, and molecule rates of the water glass, when domestic JA EUN DO sand is mixed with water glass (sodium silicate) and metallic silicon or ferro - silicon powder by the self - hardening N - PROCESS method. The results obtained from this experiment are as follows; 1) The compression strength of the mold used with metalic powder was higher and more stable than to be used ferro - silicon powder. 2) 6% water glass of 2.8 molecule rate and 1.5% of ferro - silicon of 75% purity for the N - PROCESS used with JA EUN DO sand was suitable mixing rate. 3) The compression strength increased with self - hardening time, and the PH values of the mixture of silicon powder and water glass did not change after 2 hours, but the compression strength increased steadily due to the reaction of remained silicon. 4) It is recommended to take 24 hours for self - hardening time at least.

• Journal of Korea Foundry Society
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• v.15 no.5
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• pp.477-482
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• 1995

A computer simulation model of various smelting process for melting waste sand was developed by using energy and material balance concept. This model can predict the coal, flux and oxygen consumption and the volume and temperature of off-gas. The major critical variables for smelting process can be explained by using the analysis of energy and material balance. The major conclusions were as follows; 1. The most important variables for smelting process were high post-combustion ratio, high heat transfer efficiency and refractory protection technology. 2. For saving energy in this smelting process, selection of raw materials i.e coal, flux are very important, espacially using of low volatile coal is very profitable. 3. The treatment cost of waste sand is high and environmental restriction is severe, in this reason we must be concerned in the treatment of waste sand by smelting process.

• Journal of Korea Foundry Society
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• v.9 no.5
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• pp.403-412
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• 1989

This study has been carried out to investigate into the properties of molding sands containing various core sands, $CO_2$, Shell, Furan, Pep Set and Cold Box, in the system sands using domestic active bentonite. The properties of system sands with 5% bentonite and 3% moistures containing baked core sands and no-baked core sands were varied by the ratio of core sands. The system sand containing no-baked core sands had been the poor bonding force and rough grain surface than those of the baked core sands. The L. O. I of system sand containing 30% organic binders core sands were more than inorganic binders core sands. It has been found that the no-baked core sands were necessary have to reclaim for using molding sand.

• Journal of Korea Foundry Society
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• v.3 no.3
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• pp.167-173
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• 1983

The effect of sand grain size on the various properties of mold is not only basic but important interest which we have to deal with.And the relation among the various properties of mold (strength, permeability, flowability, compactability, hardness, deformation, toughness etc.) is very complicated and inaccurate, so we can delineate the behavior of mixture (sand+water+bentonite) with experience only. Within recent years a so-called rigid-water theory has been accepted as a means of advancing logical explanations for the research aimed at delineating sand-clay-water relationships. By changing grain size or mesh no. of grain, specimens have been subjected to green compressive strength, permeability, deformation, flowability, compactablity, toughness at room temperature. Under constant mulling energy and ratio of water/bentonite, the results obtained were as follows: 1. With decreasing grain size green compressive strength of the specimen increased. 2. With decreasing grain size permeability decreased. 3. With decreasing grain size flowability and bulk density decreased but compactability increased. 4. With decreasing grain size deformation decreased but toughness increased. 5. At 60 mesh no., the properties of specimen are conspicuously changed. The reason is that the total surface area of sand grain which affects the type of bonding between sand grains is more changed at 60 mesh number.

• Journal of Korea Foundry Society
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• v.8 no.3
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• pp.271-281
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• 1988

Al-bronze has a good mechanical property, corrosion resistance and castability, so being highlighted for the new copper alloy. So, effects of alloy composition and cooling rate in the mechaincal properties and solidification behavior have been investigated. The results obtained are as follows; 1) Change in volume on solidification is larger in metal mold casting than in sand mold casting. And it decreases by the addition of Al. 2) The mechanical property in metal mold casting is superior to the one in sand mold casting, and the inclination is obvious up to 9% Al, after heat-treatment ($885^{\circ}C$, $1.5hrs\;{\rightarrow}\;W\;{\cdot}\;Q\;{\rightarrow}\;540^{\circ}C$, 3hrs) 3) By adding Al, the mechanical property is slightly increased up to 9% Al, Above 9% Al, it is increased rapidly, and is accelerated by adding Fe. 4) Cooling rate and hardness, and grain size and cooling rate are related as follows in the range of $1100^{\circ}C$ to $1200^{\circ}C$ pouring temperature. Grain size(${\mu}m$)=$929.6422{\times}cooling\;rate(^{\circ}C\;/\;sec)^{-0.51537}$ Hardness(BHN)=$765.45713{\times}grain\;size({\mu}m)^{-0.31058}$.