• Journal of Korean Society of Occupational and Environmental Hygiene
• /
• v.28 no.1
• /
• pp.100-107
• /
• 2018

Objectives: This study examines exposure to hazardous substances in the working environment caused by exposure to toxic substances produced in the aluminum die casting process in the automobile manufacturing industry. Materials and Methods: The exposure concentration levels, detection rates and time-trend of 15 hazardous factors in the aluminum die casting process over 10 years(from 2006 to 2016) were used as a database. Results: The study found that hazardous factors in the aluminum die casting process were mostly metals. The rate for detected samples was 70.6%(405 samples), and that for not detected samples was 29.4%. The noise for an eight-hour work shift showed a 49.7% exceedance rate for TLV-TWA. Average noise exposure was 89.0 dB. The maximum exposure level was 105.1 dB. Conclusion: The high numbers of no-detection rates for hazardous substance exposure shows that there is no need to do a work environment measurement. Therefore, alternatives are necessary for improving the efficiency and reliability of the work environment measurement. Moreover, to prevent noise damage, reducing noise sources from automation, shielding, or sound absorbents are necessary.

• Journal of the Korean Society for Precision Engineering
• /
• v.19 no.11
• /
• pp.200-210
• /
• 2002

In twin roll strip casting process, coupled analyses of heat transfer and deformation for the cast roll are carried out by using the finite element program MARC to examine the thermal crown. Shrink fit effect and plastic deformation are considered. The results shows that the thermal crown is greatly influenced by shrink ft and that the thermal crown for POSCO Pilot Caster 2 Copper Roll has “M” shape. The effects of several factors on thermal crown are also investigated. The amount of thermal crown increases as heat flux, casting speed, steeve thickness and casting roll width increase and decreases as the casting roll diameter increases.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.05a
• /
• pp.139-142
• /
• 2003

In this study, casting/forging process was used to produce an aluminum lower control arm for automobiles. Firstly, casting experiments were carried out to get an enhanced preform for forging the lower control arm. In the casting experiment, the effect of an additive, Sr, on the mechanical properties such as tensile strength and elongation and the microstructure of a cast preform were investigated. And a finite element analysis was peformed to determine an optimal configuration of the cast preform. Lastly, a forging experiment was carried out to make the final product of aluminum lower control arm by using the above cast preform. In the casting experiments, when 0.025% Sr was added into molten A356, the maximum values of tensile strength and elongation of the cast preform were obtained. In the forging experiment, It was confirmed that the optimal configuration of a cast preform predicted by FE analysis was very useful. The cast/forged product using designed preform was made without any defects.

• 연구논문집
• /
• s.29
• /
• pp.173-183
• /
• 1999

The vacuum investment casting process for a large gas turbine component, Inner Preswirl Support (IPS), was simulated by using commercial FEM package ProCAST(TM) with view factor radiation method. The solid fraction in mushy zone was directly measured by Differential thermal analysis(DTA-DSC mode). Three types gating design. considering liquid flow and heat release through it. were proposed. Solidification had begun at the ribs or thin sections of the IPS casting and advanced further through the upper and lower gates. The computed temperature gradient G and G/R values at 70% solidified temperature were used for prediction of microshrinkage formation during casting. The effect of mold preheat on the thermal history of the casting displayed minute effect on the microshrinkage formation.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.26 no.9
• /
• pp.1943-1951
• /
• 2002

The casting roll design is one of the most important requirements in twin roll strip casting process. Coupled analyses of heat transfer and deformation for the cast roll are carried out by use of the finite element program MARC to examine the thermal stress and deformation. The effects of several factors on thermal stress and deformation are also investigated. The amount of thermal stress increases when the ni thickness increases and when the casting speed and the copper sleeve thickness decrease.

• Journal of Korea Foundry Society
• /
• v.31 no.5
• /
• pp.243-248
• /
• 2011

Magnesium alloys have many advantages such as light-weight, high machinability, damping capacity, etc. So magnesium alloy parts have been used in transportation, mobile phone, military industries. Because of HCP atomic structure, Magnesium is very difficult in plastic deformation process, so most of magnesium products are fabricated by casting process. Magnesium alloys have low heat-capacity, high fluidity and low Fe solubility. For these reasons it is more suitable than aluminum in mass-production by casting. And various casting technologies have been developed. So casting technologies for magnesium developed recently is discussed in this paper.

• Korean Journal of Metals and Materials
• /
• v.49 no.6
• /
• pp.468-473
• /
• 2011

Determining the residual stress during casting processes is important for evaluating the mechanical properties and strength of materials and to optimize manufacturing conditions. In this study, we propose a field data interface procedure between FDM and FEM in a 3-dimensional space for analyzing the casting process and structural analysis. The casting process was analyzed using FDM and the data of the temperature distribution were converted into a format suitable for FEM analysis to calculate the thermal stress and safety factor by tightening force. The results of the coupled analysis between FDM and FEM showed that casting residual stress is an important factor in predicting life time and evaluating durability.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2001.04a
• /
• pp.905-909
• /
• 2001

The significance of casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from $420^{\circ}C$ to $450^{\circ}C$. The suitable strain rate was 1.5 $sec^{-1}$. The deformation amount of a preform in a forging process is key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of cast preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for the low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeds 0.7. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.10a
• /
• pp.261-264
• /
• 2003

Semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Many advantages are associated with this forming process at the condition that the forming operation is performed under appropriate conditions. The thixoforming process, which needs a suspension of a globular, non-dendritic solid phase in the liquid phase, is characterized by three major steps. The first step is casting of billets with a microstructure suited for thixoforming. The second step is reheating of slugs cut from these billets. The third step is injection of the semi-solid slugs into a die. In this paper, the horizontal reheating machine to obtain the optimal conditions suitable for semiu-solid die casting process was used and applied to extrusion material. It is estimated the possibility of application on semi-solid die casting with extrusion material through various results.

• Korea-Australia Rheology Journal
• /
• v.21 no.2
• /
• pp.135-141
• /
• 2009

Effect of activation energy and crystallization kinetics of polyethylenes (PEs) on the dynamics and stability has been investigated by changing rheological properties and crystallization rate in film casting process. The effect of changes of these properties has been shown using a typical example of short-chain branching (SCB) in linear polyethylenes. SCBs in linear polymers generally lead to the increase of the flow activation energy, and to the decrease of the crystallization rate, making polymer viscosity lower in the case of equivalent molecular weight. In general, the increment of the crystallinity of polymers under partially crystallized state helps to enhance the process stability by increasing tension, and lower fluid viscoelasticity possesses the stabilizing effect for linear polymers. It has been found that the fluid viscoelasticity plays a key role in the control of process stability than crystallization kinetics which critically depends on the cooling to stabilize the film casting process of short-chain branched polymers operated under the low aspect ratio condition.