• Transactions of Materials Processing
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• v.13 no.4
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• pp.319-325
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• 2004

Continuous casting machine has been experienced a rapid development to increase productivity with high casting speed and to meet consumer's strict demands for high quality. However, because most of defects and cracks are initially formed in mold and grown into surface cracks during the post process, more specific and clear investigations upon heat transfer mechanism between mold and solidified shell are necessarily needed. In this study heat transfer coefficients which shows the characteristic of heat transfer mechanism are calculated with temperatures measured in bloom mold using optimal algorithm, and thermal analysis are investigated using the calculated heat transfer coefficients. Finally uniformity of solidified shell is investigated for high carbon steel, 0.187%C from thermal analysis.

• Journal of Korea Foundry Society
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• v.13 no.6
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• pp.532-539
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• 1993

The effect of casting variables for making pure Al and Al-5wt%Si alloy rods free from any surface and inside defects was studied by adopting the horizontal continuous casting method with heated mold. The rods were cast under the casting conditions such as the mold temperature of $670{\sim}690^{\circ}C$, water flow rate of $0.2{\sim}0.6{\ell}/min$, and rod diameter of $4{\sim}8mm$, when the melt temperature and mold to cooler distance was fixed at $700^{\circ}C$ and 20mm, respectively. The results represented that the casting speed for good quality rod increased as the water flow rate increased, whereas, the casting speed decreased as the rod diameter or mold temperature increased. The statistical analysis of $2^3$ factorial design was also applied and the results represented that the averaged optimum casting speed for pure Al(302mm/min) was higher than that of Al-5wt%Si alloy(273mm/min) resulting from the difference of superheat applied. The effect of rod diameter on the optimum casting speed was the highest for pure Al as well as Al-5wt%Si alloy. The effect of water flow rate and mold temperature on the optimum casting speed was in decreasing order.

• Journal of Korea Foundry Society
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• v.14 no.6
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• pp.558-565
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• 1994

The horizontal continuous casting process with the heated mold was applied to obtain the unidirectionally solidified rods($4{\sim}8mm$ dia.) of pure copper with good surface quality. The results could be summarized as follows. 1. The unidirectional solidification of pure copper rods with good surface(mirror surface) quality could be obtained by placing the S/L interface inside the heated mold cavity even though the cast copper rods were covered with thin copper oxide layer. 2. The casting speed for 4mm dia. rods with mirror surfaces was affected significantly by the mold-cooler distance rather than the cooling flow rate when other casting conditions were fixed. 3. The casting speed was the main factor affecting the oxidation of copper during the continuous casting and the thickness of copper oxide layer decreased almost linearly as the casting speed increased.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.40 no.1
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• pp.35-40
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• 2017

A most important progress in civilization was the introduction of mass production. One of main methods for mass production is die-casting molds. Due to the high velocity of the liquid metal, aluminum die-casting is so complex where flow momentum is critical matter in the mold filling process. Actually in complex parts, it is almost impossible to calculate the exact mold filling performance with using experimental knowledge. To manufacture the lightweight automobile bodies, aluminum die-castings play a definitive role in the automotive part industry. Due to this condition in the design procedure, the simulation is becoming more important. Simulation can make a casting system optimal and also elevate the casting quality with less experiment. The most advantage of using simulation programs is the time and cost saving of the casting layout design. 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_BR2E, Computer Aided Engineering (CAE) simulation was performed with three 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 three models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflows. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

• Korean Journal of Metals and Materials
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• v.48 no.6
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• pp.551-556
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• 2010

In this report, we describe mold materials that were used to produce movable metal type by the investment casting method during the Joseon dynasty period in Korea. Samples were obtained from the Wibuinja collection, which is held by the National Museum of Korea. Most of the mold material remnants were found in the depressed areas of the movable type specimens, and we therefore performed non-destructive analyses including XRF, EDS, and XRD. Through these analyses, we were able to identify the mold remnants as hydrocerussite [trilead dihydroxide dicarbonate, $Pb_3(CO_3)_2(OH)_2$] formed in platy hexagonal crystallites. Hydrocerussite was first used to make white pigments and cosmetics in ancient Greece, but this is the first report of hydrocerussite used as mold material applied around a disposable pattern for investment casting. The results of this study will further the understanding of the production process for early movable metal type and ancient casting technologies.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.453-456
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• 2000

This paper presents experimental results on selecting optimal process parameters for UV-Vaccum casting. The UV-Vacuum casting is a relatively new process that allows very rapid mold preparation and part duplication via UV curing. Effect of various process variables such as pressure and temperature on mold strength and part accuracy was evaluated by using Taguchi method.

• Design & Manufacturing
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• v.6 no.1
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• pp.18-23
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• 2012

HI-WORTH T-32, a non-powered plasma cutter, is a portable cutter that utilizes compressor-plasma inverter. With a special air-pressure piston, the cutter is semiautomatic. When they were produced by die casting dies, the bodies or housings of the cutter have defects about 100 percent of defect rate due to blisters and thermal deformation. Therefore, they are produced by mechanical machining, which leads to a hike in material and machining costs and to the loss of productivity. And companies are left with insignificant profit margins. Besides mechanical machining, this study proposes to modify defective mold and cut down defective rate and boost productivity.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 1998.04a
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• pp.77-82
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• 1998

The Part of slot on rotary compressor which plays an important part of the reliability and performance is studied on machinability and the wear characteristics for the specimen made by sand mold and permanent mold. The experiment are used the face cutter of milling machine which make the processing surface like broaching process and rollblock wear test machine. Permanent-mold casting iron is not affected by variation of RPM of milling machine, but sand-mold cast-iron is improved to increasing RPM. Also sand-mold casting iron shows superior wear characteristic to permanent-mold casting iron. This results from harder matrix of pearlite structure and self-lubrication characteristics of graphite. And wear particles in tested oil show shape and size similar to severe wear particles of oil taken from rotary compressor. The material and surface condition of slot play important part of the reliability and performance.

• Journal of computational fluids engineering
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• v.4 no.2
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• pp.47-56
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• 1999

We developed a computer program to simulate the flow field in the presence of electro-magnetic fields. The steady, two-dimensional conservation equations for mass and momentum were solved simultaneously with Maxwell equations for electro-magnetic fields. Using this program, a numerical analysis was carried out to analyze the fluid flow in the continuous casting mold with electromagnetic brake. The effects of magnetic fields size, nozzle angle and EMBR yoke position on the flow fields in the continuous casting were investigated in the present study. The flow fields with EMBR were compared with those without EMBR. We also investigated the distribution of tracer concentration as a function of time in order to calculate their residence time in the mold with EMBR. By controlling the flow fields properly using EMBR, we can prevent the direct flow impaction on the wall which can give a damage on the mold surface and reduce surface defects of stainless steel sheet products.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.11
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• pp.1629-1636
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• 2004

The continuous casting is primarily a heat-extraction process in which the heat transfer at various cooling zones profoundly influences quality of products. So development of numerical model is necessarily needed for more specific and clear investigations upon heat transfer mechanism at mold and secondary cooling zones. In this study, heat transfer coefficients which show the characteristic of heat transfer mechanism in mold are calculated for more exact analysis with temperature measured in bloom mold using optimal algorithm, and finally the validity of cooling conditions at secondary cooling zone actually used at field fur 30 Ton bloom type continuous casting of 0.187%C is investigated. From the results of solidification analysis, the characteristic of bloom mold shows a similar tendency with that of previous studies, and optimized cooling conditions for 0.187%C are presented.