• 대한기계학회논문집B
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• 제23권1호
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• pp.12-24
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• 1999

A computer program has been developed for analyzing the two-dimensional, unsteady conservation equations for transport phenomena in the molten region of twin-roll continuous casting in order to predict the turbulent velocity, temperature fields, and solidification process of the molten steel. The energy equation of the cooling roll is solved simultaneously with the conservation equations of molten steel in order to consider heat transfer through the cooling roll. The results show the velocity, temperature and solidification pattern in the molten region with roll temperature as a function of time. The results for velocity and temperature fields with solidification are compared with those without solidification, giving different thermofluid characteristics in the molten region. We also investigated the effects of revolutional speed of roll, superheat and nozzle geometry on the turbulent flow, temperature and solidification in the molten steel and temperature fields in the cooling roll.

• 대한치과기공학회지
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• 제2권1호
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• pp.21-24
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• 1980

This experiment was intended to obtain a prefect casting body the same as the original wax patterns by melting metal into the opening of the ring. The investment ring was dried to the temperature between 600 and 700, when the wax pattern would be completely melted to leave an empty mould made in the ring. The main point to studied was the investing process for perfect casting body. This process was experimented on several important factors: the size and spatulation of investment particles, purity of wax patterns, investing time after the completion of model, and investing temperature. The results obtained from the above experiment were as follows: A desirable cast body with no fissure or pore would be mode by investing with smaller particles in the first time and with larger onces in the second, both at the temperature between 180.

• 대한치과보철학회지
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• 제38권2호
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• pp.214-225
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• 2000

The purpose of this study was to investigate the effects of investing conditions on the marginal discrepancy of conical telescope outer crown with Co-Cr-Ti alloy(Dentitan) and to compare the marginal discrepancy and the retention force of outer crowns using different pattern materials(plastic foil, casting wax, pattern resin). To evaluate the effects of investing conditions on the marginal discrepancy, patterns with plastic foil were invested under three different liquid/powder ratio conditions using phosphate bonded investment(Univest-nonprecious): standard, 10% decreased and 10% increased. At each liquid/powder ratio condition, metal ring was lined with single or double layers of ceramic ring liner. The marginal discrepancy of outer crown at different investing conditions was measured by ${\times}100$ compact measuring microscope(STM5, Olympus, Japan). For measurement of the marginal discrepancy and the retention force of outer crown using different pattern materials, the investing condition of 10% decreased liquid/powder ratio and double layers of ring liner was selected because this investing condition resulted in the best fit of outer crown. Marginal discrepancy was measured in the same way above and retention force on universal testing machine. Under the conditions of this study, the following conclusions were drawn: 1. The thickness of ring liner had more influence on the marginal discrepancy of outer crown than the liquid/powder ratio, and the acceptable marginal fitness could not be expected at the investing condition directed by investment manufacturer 2. There were no differences in the marginal discrepancy of outer crown among three different pattern materials(P>0.05). 3. Casting wax showed the greatest retention force(1640g) of outer crown, followed by pattern resin(1110g), plastic foil(820g). However, there was no significant difference between plastic foil and pattern resin(P>0.05). 4. Plastic foil showed the least variation in marginal discrepancy and retention force.

• 대한치과기공학회지
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• 제26권1호
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• pp.105-114
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• 2004

This study obtained the following consequences, as a result of the comparative analysis for the castability depending on an angle of the sprue and wax pattern in case of manufacturing dental prostheses, for the castability depending on direction, and for the castablility of sprue, which attached the reserve to each different 3.5mm roll wax(sprue wax) and to 2.5mm sprue wax. 1. As a result of the comparative analysis for the castability depending on an angle of the sprue and wax pattern, the best castability was shown when the angle of the sprue and wax pattern is 180$^{\circ}\Delta$(straight line), and the lowest castability was shown in 45$^{\circ}\Delta$, which was curved most, and there was no statistical significance. 2. As a result of the comparative analysis for the castability of an angle depending on direction, the best castability was shown in the farthest side from the direction of centrifugal casting, and the lowest castability was shown in the same side as the direction of centrifugal casting, and there was no statistical significance. 3. Given comparing the castability depending on the pattern of sprue, the better castability was shown in 135$^{\circ}\Delta$ and 180$^{\circ}\Delta$ when using 3.5mm roll wax(sprue wax), compared to attaching the reserve to 2.5mm sprue wax.

• 한국주조공학회지
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• 제13권3호
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• pp.268-275
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• 1993

In gravity die casting, die cooling systems are frequently employed with water cooling to remove the heat of the solidifying metal. Thermal modeling is an important technique in mold design for improving the productivity of the process. Computer simulation system which consists of pre-processor, main solidification simulator and post-processor has been developed for three dimensional solidification analysis of cyclic gravity die casting. The pre-processor is used for mesh generation in a PC system. The modified finite difference method is adopted for the main solidification simulation algorithm during all the casting cycles. The post-processor graphically presents the simulation results. Several experiments in automotive cast piston were carried out. The temperature variations in casting and mold with time are measured experimentally, and the results are compared with calculation results. The effects of cycle number on solidification pattern are also studied. Several experimental results for the prediction of shrinkage defects are compared with calculated results.

• 한국주조공학회지
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• 제20권6호
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• pp.400-406
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• 2000

Computer simulation for the predictions of casting defects is very important to produce high quality castings with less cost. Complicate shaped Al solenoid housing part was selected to be cold chamber die cast and a numerical simulation technique was applied for the optimization of the chill vent position and gating. A first design led to insufficient central flow. This flow left the last filled areas falling into the inner portion of the part. And last filled area did not fit the chill vent position. So these resulted in a high possibility of air entrapment in the casting and the design was not proper for the part. The design was improved by using a proper gating system, a more chill vent and proper overflow positions. New design provided a homogenous mold filling pattern and the last filled areas that being located at the overflow and chill vent. Casting plan which produce good quality solenoid housing part was established by using the computer simulation.

• 한국재료학회지
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• 제22권2호
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• pp.82-85
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• 2012

The effect of the alloy systems Al-Mg alloy and Al-Si alloy in this study on the characteristics of die-casting were investigated using solidification simulation software (MAGMAsoft). Generally, it is well known that the casting characteristics of Al-Mg based alloys, such as the fluidity, feedability and die soldering behaviors, are inferior to those of Al-Si based alloys. However, the simulation results of this study showed that the filling pattern behaviors of both the Al-Mg and Al-Si alloys were found to be very similar, whereas the Al-Mg alloy had higher residual stress and greater distortion as generated due to solidification with a larger amount of volumetric shrinkage compared to the Al-Si alloy. The Al-Mg alloy exhibited very high relative numbers of stress-concentrated regions, especially near the rib areas. Owing to the residual stress and distortion, defects were evident in the Al-Mg alloy in the areas predicted by the simulation. However, there were no visible defects observed in the Al-Si alloy. This suggests that an adequate die temperature and casting process optimization are necessary to control and minimize defects when die casting the Al-Mg alloy. A Tatur test was conducted to observe the shrinkage characteristics of the aluminum alloys. The result showed that hot tearing or hot cracking occurred during the solidification of the Al-Mg alloy due to the large amount of shrinkage.

• 대한치과보철학회지
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• 제45권4호
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• pp.522-533
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• 2007

Statement of problem: Despite of the recent development of the titanium casting system methods, the casting defects such as imperfect casting and internal porosity were frequently observed. Purpose: The purposes of this study were to compare and measure the castability, microhardness, and surface reaction between Grade 2 pure titanium and Ti-6Al-4V by casting these alloys from the different sprue design conditions. Material and methods: Depending on the sprue designs and titanium alloys, 42 ready-made wax patterns were used. By analyzing the remodeling of the cast, internal porosity, microhardness, and titanium surface layer of SEM, there were several results we observed. Results: 1. The measured castability of titanium were categorized in the ascending order: individual sprue group, runner bar group, and single group. This data are based on the statistically signigicant differences. 2. The castability of titanium has not showed the statistically significant differences among the alloys. However, CP-Ti groups were superior to Ti-6Al-4V groups by showing the noticeable castability. 3. The surface layers of the castings of all groups have showed $5{\mu}m$ titanium oxide layers irrespective of sprue designs and titanium alloys. Conclusion: From the above study results, by fabricating the restorations from the centrifugal casting machine direct sprue designs revealed better castability. As we increased the number of sprues in the wax pattern, it revealed better castability. The castability of pure titanium rather than that of Ti-6Al-4V was remarkable. To fabricate the complex forms of the restorations, further researches on the efficient sprue designs and titanium alloys must be made.

• 한국CDE학회논문집
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• 제6권4호
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• pp.263-270
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• 2001

In stamping-die manufacturing, the first step is to build die patterns for lost wax casting process. A recent industry trend is to manufacture the die pattern using 3-axis NC machining. This study identifies technical considerations of the pattern machining caused by the characteristics of Styrofoam material, and proposes technical methods related to establishing a process plan and generating tool paths for optimizing the pattern machining. In this paper, the process plan includes the fellowing three items: 1) deter-mining a global machining sequence-a sequence of profile, top, bottom machining and two set-ups, 2) extracting machining features from a pattern model and merging them, and 3) determining a machining sequence of machining features. To each machining feature, this study determines the machining start point, generates the approach tool path, and proposes a tool path linking method fur reducing the distance of the cutter rapid motion. Finally, a smooth tool path generation and an automatic feedrate adjustment (AFA) method are introduced far raising the machining efficiency.

• 대한기계학회논문집A
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• 제34권7호
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• pp.919-928
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• 2010

연속주조 시에 폭변경 속도를 향상시키기 위해 폭조정의 4 가지 패턴에 대해 연구하였다. 주요 사항은 폭변경 장치의 구동력을 최소화하고, 몰드 내의 응고막의 변형해석 모델을 개발하고, 폭변경 속도 상승을 제한하는 주요인자를 도출하는 것이다. 폭변경 실험을 근간으로 4 개 패턴의 주요 특징을 도출하였고, 각 패턴에 대한 힘을 비교하였다. 실험은 각 패턴의 구동력 비교를 위해 동일한 주조속도에서 수행하였다. 응고막변형 해석모델의 변수를 조정하기 위해 실험결과를 모델에 적용하였다. 폭변경 속도를 상승시키고, 구동력을 저감시키기 위해 패턴의 변수를 제어하였다. 가장 효율적인 패턴은 고속패턴이었으며, 구동력을 저감하기 위한 주요인자는 구동장치가 이동할 때의 기울기였다.