• 한국주조공학회지
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• 제42권6호
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• pp.331-336
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• 2022

본 연구에서는 LPG 자동차용 연료탱크 밸브 제조를 위한 주조방안에 대하여 연구하였다. 대상 밸브에는 그 내부에 두 개의 돌기가 존재한다. 돌기 내부에는 기공 결함이 흔히 발생하였다. 이러한 주조 불량을 최소화하기 위하여 대상 제품의 다이캐스팅 과정에서 용탕 흐름에 대한 컴퓨터 시뮬레이션을 수행하였다. 주요 공정 매개변수는 인게이트 위치, 제품 방향 및 주입 속도였다. 또한 진공 다이캐스팅의 사용을 고려하였다. 기공 결함의 위치는 모든 인게이트 위치와 제품 방향에 대해 거의 동일했다. 한편 주입 속도의 변화가 공기 포획의 위치에 영향을 미친다는 것을 알 수 있었다. 진공 다이캐스팅의 경우 기공 결함의 위치는 이전의 경우와 비슷했지만, 실제 상황에서는 진공으로 인해 기포가 많이 줄어들 것으로 예상된다.

• 한국정밀공학회지
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• 제26권3호
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• pp.88-97
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• 2009

The vacuum die casting techniques can diminish the porosity of products and provide better surface appearance by the ordinary high pressure die casting process. The vacuum system can also reduce the cold laps in the die casting process and minimize the overflow pockets of the die. The vacuum system does not need high pressures to die cast compared to the ordinary die casting process, and so enables die casting of large parts for a given machine size. Parts made by the vacuum system have higher strength and more elongation than parts made by the ordinary die casting systems. In this paper, we designed and produced the Magnesium seat frames using the vacuum die casting processes. The new Magnesium seat frame was designed to satisfy safety regulations. Some safety test procedures of the seat frame were simulated by the finite element method. We obtained 10% weight reduction by design modification of seat frames compared to the current model. Flow simulations were carried out to minimize the trial and error in producing the parts. The die casted parts using vacuum systems resulted in better mechanical characteristics and no defects compared to those without vacuum systems.

• 한국자동차공학회논문집
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• 제20권4호
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• pp.52-59
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• 2012

The subframe has been generally manufactured by using stamped steel material. Recently, automotive designers are considering aluminum as lightweight material. This paper describes the development process of an aluminum subframe which is made by high level vacuum die casting process, which is beneficial for minimizing gas contents and material properties. The weight of manufactured subframe is reduced by 4kg with the comparison of steel subframe. The aluminum subframe is packaged for the current vehicle layout and the imposed requirement is to attain a better structural performance that is evaluated in terms of mounting stiffness, noise and vibration, and endurance performance. The NVH evaluation results show that sound level is decreased by 8dB with the help of high roll-rod mounting stiffness as well as high structural modes.

• 한국전자거래학회:학술대회논문집
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• 한국전자거래학회 2001년도 International Conference CALS/EC KOREA
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• pp.105-109
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• 2001

성형의 종류 ◈금속 성형 ㆍ 스탬핑(Stamping) ㆍ 정밀 블랭킹(Fine Blanking) ㆍ 딥 드로잉(Deep Drawing) ㆍ 다이캐스팅(Die Casting) ㆍ 인베스트먼트 주조(Investment Casting) ㆍ 분말 야금(Power Metallurgy) ㆍ 인발(Wire Drawing) ㆍ 압출(Extrusion) ㆍ 단조(Forging) ㆍ ㆍ코이닝(Coining) ㆍ... ◈비금속 성형 ㆍ 사출(Injection) ㆍ 압축(Compression) ㆍ 블로우 성형(Blow Molding) ㆍ 진공 성형(Vacuum Molding) ㆍ 발포 성형(Foam Molding) ㆍ 피복(Encapsulation) ㆍ 회전식(Rotational) ㆍ 주조(Casting) ㆍ 적층(Laminating) ㆍ 압출(Extrusion) ㆍ...(중략)

• 한국결정성장학회지
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• 제31권1호
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• pp.24-31
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• 2021

최적의 조건에서ADC12 알루미늄 합금을 다이캐스팅 기법으로 제조하여 구조적, 기계적, 열적 성질을 연구하였다. 또한 진공에서 후속 열처리한 ADC12 알루미늄 합금의 기계적 물성 변화를 규명하였다. 방사광 X-선 회절 및 energy dispersive X-선 화학조성 분석법을 통하여 ADC12 합금은 알루미늄 기저에 알루미늄과 구리의 화합물인 Al2Cu 및 AlCu3 상이 결정질 형태로 분포하고 있음을 규명하였다. 대표적인 기계적 물성값인 인장강도와 연신율은 각각 307.9 ± 9.1 MPa와 2.98 ± 0.62 %이다. 기존 보고보다 우수한 열전도도(129.3 ± 0.27 W/m·K)와 비이커스 경도값(Hv = 130)을 나타낸다. 후속 열처리 결과, 200℃까지는 기계적 물성치가 일정하게 유지되었으나, 이후 500℃까지 열처리 온도를 증가시킬 경우에는 인장강도와 비이커스 경도가 점진적으로 감소하였다. 이는 열처리 도중 미세조직이 안정화되면서 인성과 연성이 향상되었기 때문이다.

• 한국주조공학회지
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• 제31권2호
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• pp.71-78
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• 2011

This study aims to investigate the formability of bipolar plates for fuel cell fabricated by vacuum die casting of ALDC 6. Cavity shape of mold is thin walled plate (size: $200mm{\times}200mm{\times}0.8mm$) with a serpentine channel (active area: $50mm{\times}50mm$). Before bipolar plate was made by HPDC, computational filling behavior and solidification was performed by MAGMA soft. The final mold design for location and direction of channel was determined by computational simulation. Also, according to injection speed conditions, simulation result was compared to actual die casting experimental result. When vacuum pressure, injection speed of low and high region is 350 mbar, 0.3 m/s and 2.5 m/s respectively, products had few casting defects. On the other hand, at the same as injection speed, without vacuum pressure, products had many casting defects between end of the channel and overflow.

• 한국주조공학회지
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• 제32권2호
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• pp.65-74
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• 2012

In this paper, we present the results of our studies on optimal die design towards development of a vacuum die casting process to fabricate fuel cell bipolar plate with micro-channel array. Cavity and overflow shape is designed by computational filling analysis of MAGMA soft. Optimal die design consists of seven overflows at the end of cavity and three overflows at each side wall of cavity. The molten metal that passed the gate and reached the side wall flowed into the side overflow, no turbulent flow occurred, and the filling behavior and velocity distribution were uniform. In addition, partially solidified molten metal passing through the channel was perfectly eliminated by overflow without back-flow. When vacuum pressure, injection speed of low and high region was 300 mbar, 0.3 m/s and 2.5 m/s respectively with Silafont 36 die casting alloy, sound sample without casting defects was obtained. The experimental results are nearly consistent with simulation results.

• 소성∙가공
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• 제21권3호
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• pp.195-201
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• 2012

A vacuum ladling die casting system is suggested as a means to obtain a high vacuum level. A high vacuum of 17.8 mmHg is obtained by sealing the inner space of the mould. The sample product is a rear-head housing for an auto-compressor, and the die-casting with 6-cavities was conducted. The flow analysis shows that the filling speed during vacuum ladling is faster than for a non-vacuum system. The air holes in the sample product were too small to be seen with the naked eye in X-ray films. Density tests show that the high vacuum ladling system reduces the internal porosity as much as 57.8% when compared to the non-vacuum system. A defective rate of only 0.17% was found from leak testing. The results of this research prove that the high vacuum die-casting process is useful for manufacturing of aluminium components under high internal pressure.

• 산업경영시스템학회지
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• 제35권2호
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• pp.196-203
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• 2012

When manufacturing die casting mold, generally, the casting layout design should be considered based on the relation between injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects were differentiated according to the various relations of the above conditions. High-qualified products can be manufactured as those defects are controled by the proper modifications or the changes of die casting mold with the conditions. In this research, the proper manufacturing method was derived intensively for reducing the defect of the internal porosity of steering wheel housing which is very complicated to achieve a good mold design. The method was also derived for minimizing and for guaranteeing the product quality through the analysis of the casting problem and the deduction of alternative plans.

• 소성∙가공
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• 제8권5호
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• pp.491-497
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• 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.