• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.316-321
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• 2000

Die Casting is one of the forming methods to manufacture large number of products with short period time and clean surface by high forming pressure and temperature of cast alloy. Die design is composed of selection of cast alloy, design of die casting product, runner and gate design etc. In reality, however, die design of die casting has been performed by trial and error method, which cause economic and time loss. This paper describes a research work of developing computer-aided design of die casting product and die design. Approach to the CAD system has been written in AutoLISP on the AutoCAD with personal computer. In this study, die design system for gate of die casting process has been developed to present algorithm for automation of die design, especially runner-gate system. As forming process and die design system using 3-D geometry handling are integrated with technology of process planning, die design is possible to set. In addition, specific rules and equations for the runner-gate system have been presented to avoid too many trails and errors with expensive equipment. It is possible for engineers to make automatic and efficient die design of die casting and it will result in reduction of expense and time to be required. An example is applied to cap-shaped casting using proposed algorithm.

• Transactions of Materials Processing
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• v.21 no.3
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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.

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

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2013.05a
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• pp.865-866
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• 2013

• Journal of Korea Foundry Society
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• v.17 no.6
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• pp.552-559
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• 1997

주조방안설계를 위한 pre-processor, main-solver 그리고 post-processor로 구성된 통합 응고해석 시스템을 개발하였다. Pre-processor는 퍼스널 컴퓨터에서 사용되는 상용 CAD 프로그램인 AutoCAD를 사용하였다. Main-solver는 주조과정중의 충진거동을 해석한 유동해석 프로그램과 3차원 열전달 응고해석을 통합하여 냉각수 시스템으로 제어되는 금형 반복주조법에서의 응고양상을 해석할 수 있다. Post-processor는 cavity내의 용탕충진거동, 주형내의 온도분포, 응고시간등을 3차원 그래픽으로 처리할 수 있게 설계하였다. 개발된 시스템의 현장적용 가능성을 검증하기 위하여 대형주강 밀하우징, 자동차휠 주조용품, 밸브블럭등의 시제품의 열유동해석에 적용하였다. 본 연구에서 개발된 CastDesigner는 중소기업형 주조현장에서 PC용 CAD/CAE system 구축을 통한 최적주조방안 설계용 열유동해석 프로그램으로 사료된다.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.6
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• pp.28-34
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• 2008

Mg alloy is widely used for the IT, auto and consumer electronics industries. Semi-solid casting(SSC) of magnesium alloys is used to produce high quality components. SSC process is analogous with the injection molding of plastics. The high strength and low weight characteristics of magnesium alloys render the high-precision fabrication of thin-walled components with large surface areas. To produce thin-walled magnesium alloy parts, SSC process parameters on the quality of the finished product should be clearly studied. In this paper, to select optimal process parameters, Taguchi method is applied to the optimal design of the process parameters in the SSC process. The die temperature, injection velocity and barrel temperature of the SSC process are selected for the process parameters. The effectiveness of the optimal design is verified through the CAE software.

• Journal of Korea Foundry Society
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• v.33 no.5
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• pp.210-214
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• 2013

Recently, the automotive industry has replaced cast iron to lightweight materials like aluminum for engine efficiency of automobiles and an emission control by government. In this paper we studied two auto parts manufacturing methods using an alloy of A356. That is gravity casting and H-NCM Rheo-diecasting forging. We analyzed the microstructure and mechanical properties for this method. In Microstructure analysis results, H-NCM Rheo-diecasting forging has more finer microstrucre and better forging effect. Resulting in better mechanical properties than gravity forging.

• Journal of the Korea Institute of Information and Communication Engineering
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• v.20 no.8
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• pp.1546-1552
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• 2016

In addition, because it uses preheating to dissolve an alloy in general, it is hard to regulate the appropriate melting temperature of the alloy and brewing time and shows the defect of the supplementation thing due to the super-heating. Once the alloy is molten and then most of the casting by attaching a sight glass or non-contact temperature sensor is suitable casting temperature the operator pressing a button to generate a centrifugal force to inject the molten alloy into a crucible in the casting ring. These results, and most of the cast temperature is too high or too low to generate a lot of casting defects do not get into a uniform cast body. In this paper, we developed a dental casting machine for high frequency using a single temperature sensor which can measure the actual temperature of the alloy than the temperature of the external non-contact measurement using a temperature sensor.

• Transactions of Materials Processing
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• v.26 no.6
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• pp.372-377
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• 2017

In this paper, an effective design procedure was proposed to design the rib of die structure for auto-body member with ultra-high strength steel (UHSS) having ultimate tensile strength (UTS) of 1.5 GPa. From analysis results of the die structure, structural safety of the die was evaluated with information such as displacement and von-Mises stress. It was concluded that the casting part could be designed in order to reduce tool deformation. A design guideline of the die structure was proposed, especially for the rib structure in the casting part with an optimization scheme and local reinforcement concept. Simulation result following the design guideline fully explained that stability of the tool structure could be obtained simultaneously with weight minimization.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.18 no.2
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• pp.130-136
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• 2009

Semi-solid casting(SSC) of magnesium alloys is increasingly being used to produce high quality components. This process is similar to the injection molding of plastics and is called thixomolding. Using this process, higher strength, thinner wall sections and tighter tolerances without porosity are obtained. The high strength and low weight characteristics of magnesium alloys render the high-precision fabrication of thin-walled components with large surface areas. They are widely used for the IT, auto and consumer electronics industries. However, warpage of the thin-walled sections degrade quality of the parts produced in the SCC process. To produce thin-walled magnesium alloy parts, the geometry of gating system on the quality of the finished products should be clearly studied. In this paper, to minimize warpage of the thin-walled sections, Taguchi method is applied to the optimal design of the gate geometry in the thixomolding process. Width, height, length and angle of the gating system are selected for the robust design parameters. Effectiveness of the robust design is verified through the CAE software.