• Korean Journal of Materials Research
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• v.16 no.11
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• pp.668-675
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• 2006

In the partial squeeze casting process, the filling behavior of liquid metal and solidification pattern in thick area have significant influence on the quality of casting products and die life. For the optimal casting design of automobile transmission gear housing, various analyses were performed in this study by using computer simulation code, MAGMAsoft and the simulation results were compared and analyzed with experimental results. By air pressure criteria, internal porosities caused by air entrap during the mold filling were predicted and reduced remarkably by modification of gating system. Also, optimal squeeze-time lag to apply partial squeeze pin in thick area was calculated and the castings was free from shrinkage defects with the result of solidification analysis. Consequently, casting design for automobile transmission gear housing was optimized and approved by Computer Tomography.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.03a
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• pp.165-171
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• 1996

Recently, to improve the productivity in the continuous casting process, thin slab continuous caster which is one of the new steelmaking technologies by a high speed casting has been introduced. In the process of the thin slab continuous cast, there is more possibility than convnetional one that the deformation be occurred by the bulging of solidified shell, since the thickness of soliidfied shell is very thin as much as 60mm after the casting is finished. In some cases of severe bulging, there might be more breakout. In this paper, using finite difference method , solification analysis of slab is made as well as the thicknessof solidified shell and temperature are calculated. Also, based on the data of the calculated temperature, the deformed behavior of solidified narrow face is anlayzed with the MARC which is a package program for finite element analysis.

• Journal of Korea Foundry Society
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• v.18 no.6
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• pp.555-562
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• 1998

Modified fluid critical solid fraction method was utilized as a prediction parameter to describe the shrinkage formation including the position, shape and amount of shrinkage cavities. A numerical scheme was implemented adapting this method for the evaluation of solidification defects in various casting processes. In the present numerical code, the form of shrinkage cavity can be simultaneously determined when an isolated loop is predicted to occur by the fluid critical solid fraction method. An auxiliary parameter, shrinkage potential, was also used in order to calculate the amount of residual liquid during solidification. Solidification analysis was carried out for the validation of the present scheme. It was shown that the calculated results were in good agreement with those of practical casting runs in all of the casting processes envolved in the present research. It may be concluded that the present program successfully predicts the detailed shrinkage formation behavior without the consideration of interdendritic fluid flow analysis.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.1
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• pp.180-185
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• 2002

Aluminum casting/forging process is used to produce an aluminum tie-rod end for the steering system of automobiles. Firstly, casting experiments were carried out to get a good preform for forging the tie-rod end. In the casting experiment, the effects of additives, Ti+B, Zr, Sr, and Mg, on the mechanical properties and the microstructure of a cast preform were investigated. And a finite element analysis was performed to determine an optimal configuration of the cast preform. Lastly, a forging experiment was carried out to make the final product of aluminum tie-rod end by using the above cast preform. In the casting experiments, when 0.2% Ti+B and 0.25% Zr were simultaneously added into molten Al-Si alloy, the highest values of tensile strength and elongation of the cast preform were obtained. When 0.04% Sr were added into the molten aluminum alloy, the finest silicon-structure was observed in the cast preform. The highest hardness was obtained when 0.2% Mg was added. In the forging experiment, It was confirmed that the optimal configuration of a cast preform predicted by FE analysis was very useful. The hardness of a cast/forged product using designed preform was superior to that of required specification.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.1211-1212
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• 2010

• Journal of Korea Foundry Society
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• v.27 no.3
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• pp.101-114
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• 2007

• Journal of Korea Foundry Society
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• v.33 no.1
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• pp.32-40
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• 2013

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.06a
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• pp.695-696
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• 2009

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.10a
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• pp.387-388
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• 2009

• KSCE Journal of Civil and Environmental Engineering Research
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• v.33 no.4
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• pp.1281-1293
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• 2013

A sophisticated finite element model is illustrated to analyze the behavior of Prefabricated Parallel Wire Strand(PPWS) sockets for main cables of suspension bridges. An orthotropic model is proposed for the casting material by considering both effects of individual wires and a casting alloy, and the contact between surfaces of a socket and a casting alloy is idealized by using the Coulomb friction and the surface-based contact model. The proposed FE model is verified by comparing the strain distributions obtained from the tensile test and FE analysis. The mechanical behavior of a socket is investigated with respect to the variation of the frictional coefficient. The result shows that the friction between surfaces significantly diminishes the stress concentration of a socket and a casting alloy, and the normal stress from the design equation represents the averaged value of the upper and lower quartiles in the distribution of contact stresses between a socket and a casting alloy.