• Journal of the Korean Society for Precision Engineering
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• v.24 no.6
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• pp.131-137
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• 2007

In metal casting process, it is very difficult to predict the form accuracy of cast part and reduce repeatability error. In this study, the variations of form accuracy were measured in the process of metal cast prototyping, where RP part is manufactured from CAD model in the first, and then, wax part is cast in the vacuum environment using the RP part as master model, and finally metal prototype is cast using ceramic mold and the wax part as pattern. To investigate the variations of form accuracy, the averages and standard deviations of error distribution of the parts measured by 3D scanner were compared. It was observed that the biggest shrinkage is generated during the extraction of wax part in the second step and the biggest deterioration of form accuracy is generated during the metal part casting in the last step.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.8 s.185
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• pp.203-210
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• 2006

This paper focuses on the development of RT technology suitable for manufacturing a small quantity of metal prototype of a precise part from an RP master. Dimensional accuracy and surface roughness are evaluated from Thermojet part of a 3D printer, and effective post-processing method is introduced. Investment casting is done using a prototype built from 3D printer as a wax pattern. Ceramic shell investment casting technique is developed to build a prototype with materials mostly wanted. Also, experimental result shows this research is very useful in manufacturing of a small quantity of functional part or a test part of a specific material.

• Journal of Mechanical Science and Technology
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• v.17 no.12
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• pp.2010-2018
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• 2003

Although continuous casting process has highly developed, there still remain many problems to be considered. Specifically, two vortex flows resulting from impingement against narrow walls make a flow field unstable in a mold, and it is directly related to internal and external defects of steel products. To cope with this instability, EMBR (Electromagnetic Brake Ruler) technique has been lately studied for the stability of molten steel flow, and it is revealed that molten steel flow in a mold can be controlled with applied magnetic field. However, it is still difficult to clarify flow pattern in an EMBR caster due to complex correlations among variables such as geometric factors, casting conditions, and the place and the intensity of charged magnetic field. In the present study, flow field in a mold is focused with different conditions of electromagnetic effect. To accurately analyze the case, three dimensional low Reynolds turbulent model and appropriate boundary conditions are chosen. To evaluate the electromagnetic effect in molten steel flow, dimensionless numbers are employed. The results show that the location and the intensity of the applied magnetic field significantly influence the flow pattern. Both impingement and internal flow pattern are changed remarkably with the change of the location of applied magnetic field. It turns out that an insufficient magnetic force yields adverse effect like channeling, and rather lowers the quality of steel product.

• Journal of Korea Foundry Society
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• v.7 no.2
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• pp.122-132
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• 1987

Full mold casting process is a new technique offering numerous advantages and promising possibilities. The present study is aimed to bring out the results of experiments carried out to study the effect of pattern coatings on the solidification of 99.5% pure aluminum plate-shaped castings in the various sand molds and the thermal behavior of the molds. The results of the investigation indicate that (i) with increase in pattern coating thickness, the relative chilling power decreases gradually for silica and increases for zircon coating, and (ii) the application of a pattern coating significantly reduces the maximum interface temperature by the mold which is more pronounced in the case of thinner mold wall. The investigation also indicates that Chvorinov's rule is not found to be valid for the casting in the full mold, with or without pattern coating. Therefore in full mold process, the pattern coating thickness will be a very important parameter in the study of thermal behavior.

• Journal of Technologic Dentistry
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• v.21 no.1
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• pp.77-85
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• 1999

When producing partial denture using a Chrome-cobalt alloy being used universally, 45 pattern of them to compare casting characters according to 5 burying methods(special ring method, plastic ring method, general metal ring method) and 5 casting directions(straight, upper, lower, left and right directions) were compared and evaluated. The results were as follows : 1. The comparison of casting characters in accordance with burying type shows that the special ring method to install blind air vent using utility wax was the highest rate of 76.9%, followed by 69.1% of the plastic ring to cast without ring and 61.1% of the metal ring method being used universally respectively. Namely the special ring method was best. The significant level was P<0.05 statistically. 2. The comparison of casting character in accordance with casting directions shows that the straight casting was the highest of 77.9%, and followed by right casting of 74.2%, left casting of 66.7%, upper casting of 63.5%, and lower casting of 62.9% respectively, Namely the straight casting was best.

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.1
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• pp.56-61
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• 2001

This work is concerned with the development of a new plaster die casting process the combines pressurization and vibration for the prototyping of die-castings, and also with a plaster die-casting machine that has a structure quite similar to that of an ordinary die casting machine. The machine utilized an air cylinder for pressurization and a magnetic actuator for vibration. A rapid prototyped pattern is made by the LOM process to prepare a plaster mold. In the process, a plunger int he developed machine simultaneously pressurizes and vibrates the molten metal to fill the plaster mold completely and to facilitate the creation of nuclei in the molten metal, respectively. The developed machine produced a prototype of an end clutch cover with a remarkable improvement in mechanical properties.

• The Journal of Korean Academy of Prosthodontics
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• v.41 no.4
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• pp.421-439
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• 2003

Statement of problem : It is difficult to obtain a good titanium casting body using the traditional sprue design because of high melting point of Ti, and the low fluidity and high reactivity of molten Ti. Purpose : A new sprue design for titanium casting bodies needs more trial and error. In order to decrease the number of trial and error, computer simulation(MAGMASOFT, Magmasoft Giessereitechnologie GmbH, Achen, Germany) was used to optimize sprue design in U-shaped implant superstructures. Material and method : Five kinds of sprue were examined for the design of the sprue former for titanium casting: Sprue design A(sprue length 4 mm, rectangular shape, 4 sprues), Sprue design B(sprue length 4 mm. round shape. radius 2 mm, 7 sprues), Sprue design C (sprue length 2 mm, round shape, radius 2 mm, 7 sprues). Sprue design D (sprue length 2 mm, cone shape, large radius 3mm. small radius 2mm, 7 sprues), and Sprue design E( sprue length 2 mm. one unit channel shape). Sprue design F(sprue length 2mm, one unit channel shape) was also examined for the design of the customized sprue former in the Biotan system(Schutz Dental Gmbh, Germany). The casting bodies were taken in Sprue design A, Sprue design D, Sprue design E, and Sprue design F in the Biotan casting system. The numerically predicted defects were compared with the experimental dental castings by the radiographic and sectional view observations. Results : 1. According to the result of computer simulation, turbulence during mold filling was decreased in the sequence of Sprue design F, Sprue design E, Sprue design D, Sprue design C, Sprue design B, and Sprue design A. 2. The calculated solidification time contours indicate that hot spot was moved from the casting body to the sprue button in the sequence of Sprue design A, Sprue design B, Sprue design C, Sprue design D, and Sprue design E. The filling pattern of Sprue design F was similar to that of Sprue design E. 3 The predicted filling pattern shows that less turbulence was found in the customized sprue former than in the standard sprue former. 4. According to the results of the radiographic and cross sectional observations, casting defects less than 1mm were found at the center of a casting body with Sprue design E and Sprue design F. However, larger casting defects of 4mm were found in a casting with Sprue design A. 5. The predicted casting porosity was similar to that of the real casting. Conclusion : One unit channel-type and customized sprue former can be recommended. Further research and developement of various sprue designs using computer simulation in necessary to optimize casting design, in order to reduce the formation of casting defects in implant titanuim super-structures.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.3 no.2
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• pp.110-114
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• 2002

The master pattern manufacturing process is one of the most important processes in jewelry industry because the process takes 20% of total jewelry manufacturing costs. The previous jewelry manufacturing process has many steps of "rough design${\leftrightarro}$ detailed drawing${\leftrightarro}$ wax pattern manufacturing ${\leftrightarro}$ lime soda flask mold manufacturing ${\leftrightarro}$ silver master pattern manufacturing ${\leftrightarro}$ mass production of wax pattern ${\leftrightarro}$ investment casting process ${\leftrightarro}$ final jewelry product." A novel process that reduces processing steps by using a rapid prototyping system (RP) has been suggested. The process is "3D CAD design ${\leftrightarro}$ DuraForm mold manufacturing by RP ${\leftrightarro}$ manufacturing master pattern by low melting alloy ${\leftrightarro}$ mass production of wax pattern ${\leftrightarro}$ investment casting process${\leftrightarro}$ final jewelry product." Molds are made with DuraForm powder, of which melting temperature is 19$0^{\circ}C$, by a selective laster sintering type RP. An alloy of Pb-Sn-Bi-Cd, of which melting temperature is $70^{\circ}C$, is casted in the DuraForm molds. Spheres and rings of diameter 20 mm are made by this process. The dimension deformation rate is less than 2%, and the post processing of the castings is convenient. The casting made by the suggested process can be used as a master pattern of jewelry products.of jewelry products.

• Proceedings of the KSME Conference
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• 2007.05b
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• pp.2050-2054
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• 2007

This study numerically and experimentally investigated on thermal strain analysis of aluminum alloy casting mold using metal foundry. To predict the numerical result of thermal strain in Al alloy casting mold during the cooling process, it is performed the investigation of temperature distribution, stress and displacement based on the physical properties of Al alloy. In results of this study, Al alloy casting mold represented rapidly cooling graph during initial 20minutes after beginning cooling process, therefore value of stress and displacement is rapidly changed during initial 20minutes after beginning cooling process. In addition to, temperature distribution obtained by experiment confirmed corresponding pattern then compared numerical analysis with experiment. These results are distribute to make the effective and the high precision casting mold.

• Journal of the Korean Society of Industry Convergence
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• v.21 no.1
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• pp.1-8
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• 2018

The purpose of this study is to develop a high-strength, high-toughness, thin-walled aluminum shock absorber housing product by applying a high vacuum die casting method to improve internal gas defect and formability. The analysis program dedicated for the casting was used because it was too costly and time-consuming to adopt the gating system design. The final casting plan was designed based on the flow pattern of the material filled into the mold and the result of air pressure and air pocket after the material was completely filled in the mold. Gaty shape was designed as a split type. The runner was designed to have the same shape as the initial inlet curve of the cavity, and the flow of the molten metal was prevented from turbulent flow. The most favorable results were obtained when the injection speed was $V_2=4.0m/s$. Defects on pores were reduced by applying high vacuum level inside the mold.