• Journal of Korea Foundry Society
• /
• v.24 no.2
• /
• pp.63-70
• /
• 2004

Foundry techniquews for large steel casting depends on the skills of foundrymen considerably. Especially, the problem of reducing casring surface defects is difficult to clear numerically. Statistical analysis by using wuantification theory for hot tear and sand inclusion, and multiple regression analysis for dimensional defects have been shown to be examples of solving this difficulty. Many causes of surface defects can be evaluated by these analyses. These evaluations serve as the base data of defect reduction and contribute to the constant improvement of casting quality and quality enhancement activity. The system to perform quality enhancement activity was developed and it proved very useful for transfering foundry techniques and skills from the old to young generations.

• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• v.8 no.1
• /
• pp.142-149
• /
• 1999

A machine frame has been manufactured by casting. However, due to the development of the industrial society, 3-D duties was refused. Especially, the declination of the casting industry makes it difficult to produce the frame. Many companies still manufacture the small casting products. The large casting products are extremely limited and manufactured for their own use. Therefore, it is difficult to keep the term of order. In this study, the characteristics of steel structure which is produced by welding were identified in the view of mechanical strength of steel structure which is produced by welding were identified in the view of mechanical strength to substitute steel structure for casting frame. But welding structure has the residual stress, HAZ and welding deformation. Residual stress and HAZ especially cause crack growth. The proposed steel structure, based on the simulation and experiment(tensile curve and S-N curve), can reduce not only the producting term but also the weight of the frame.

• 한국전산유체공학회:학술대회논문집
• /
• 2003.10a
• /
• pp.12-12
• /
• 2003

• Journal of Korea Foundry Society
• /
• v.17 no.5
• /
• pp.465-471
• /
• 1997

An integrated computer program consisting of a pre-processor, main solver, and post-processor was developed for the design of large steel castings. The pre-processor, based on the AutoCAD, enables the user to produce approval drawings, casting design drawings and mesh diagrams in sequence using a personal computer. In the main solver, two numerical models were employed; one models the fluid flow during mold filling, and the other models the heat transfer and solidification. The post-processor can be used to present simulation results such as flow pattern, mold filling sequences, solidification times, temperature gradients and location of shrinkage defects by color graphics. In order to validate the applicability of the present integrated program, a series of experiments on simple-shaped steel castings were carried out. After the validation of the present model, it was applied to the casting design of the large steel anchor of an SC42 alloy. Various solidification parameters such as a temperature distribution and a solidification time in the casting and the mold were compared with those obtained experimentally. Simulated results predicting shrinkage defects were in good agreement with those obtained experimentally. It was found that the present method can be successfully applied to the quantitative casting design for complex-shaped large steel castings.

• Journal of Korea Foundry Society
• /
• v.10 no.2
• /
• pp.110-115
• /
• 1990

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.05a
• /
• pp.52-56
• /
• 2008

Inclusions in forged large steel ingots of plan carbon steel and tool steel are investigated using optical microscop observation and WDX analysis. The large nonmetallic inclusions which is over $30\sim300{\mu}m$ in their diameter were observed in the samples that has been no good on a nondestructive test. The most of the inclusions were consist of some kind of oxides, ${Al_2}{O_3}$, $SiO_2$, CaO, MgO in forms of particles and glassy with an iron particles. The experimental large steel ingot was cast with a pouring temperature which is about ten centigrade higher than the field standard. The inclusions were observed in the test ingot are the smaller than that was in a usual forged steel ingot and is spherical shape with a glassy agglomerated ${Al_2}{O_3}-SiO_2-CaO-MgO$ particle. The pouring temperature is affected on removing the nonmetallic inclusions during the solidification by a floating mechanism.

• Proceedings of the KSR Conference
• /
• 2008.06a
• /
• pp.2046-2052
• /
• 2008

For the lighting of vehicles structural casting components of aluminum casting alloys are substituted for those of steel or iron. For the manufacturing of large-scale premium quality aluminum castings the developments of a new casting process and a heat treatment process are necessary. The optimum casting design and heat treatment condition for large-scale castings are drawn with the help of Z-Cast software for the casting process analysis in this study. Low pressure sand casting method is applied successfully to produce air bag support components of D357 aluminum casting alloy.

• Journal of Korea Foundry Society
• /
• v.11 no.1
• /
• pp.54-62
• /
• 1991

A computer program which consists of pre-processor, main solidification simulator and post-processor has been developed for three dimensional solidification analysis of steel castings. The pre-processor is used for mesh generation in a small personal computing system. The modified finite difference method is adopted for the main solidification simulation algorithm. The post -processor graphically presents the simulation results and shows the formation of shrinkage defects. Several experiments on large steel castings in sand mold were carried out. The temperature variations in casting and mold with time are measured experimentally, and the results are compared with calculation results. Several numerical examples for the prediction of shrinkage cavity in large steel casting of SC42 and SCNCrM2 alloys are compared with experimental results. The effect of sleeve and chills on solidification patterns are also studied. Formation of shrinkage defects for the three cases of experimental castings are relatively well predicted by present model.

• Journal of Korea Foundry Society
• /
• v.9 no.1
• /
• pp.29-38
• /
• 1989

• Korean Journal of Metals and Materials
• /
• v.50 no.2
• /
• pp.129-135
• /
• 2012

High speed casting technology is an attractive method to increase the productivity of continuous casting. However, high speed casting causes flow instability of molten steel in a mold. In this study, Large Eddy Simulation (LES) has been performed to identify the characteristics of mold flow for various shapes of submerged entry nozzles. The LES code has been newly developed to efficiently compute the two-phase flow by using the Fractional Step Method (FSM) combined with the Volume of Fluid (VOF) method. The Immersed Boundary Method was used to implement the shape of the submerged entry nozzle. Three cases of discharge angle of the submerged entry nozzle were computed and compared. The current results shed light on improving shape design of a submerged entry nozzle.