• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2004.10a
• /
• pp.152-155
• /
• 2004

In the semi-solid die casting process, the important thing is the flow behaviors of semi-solid material. The flow patterns of semi-solid material can make the defects during die filling. To control of the flow patterns, is very important and difficult. In this paper, the flow behaviors of the semi-solid A356 alloy material during die filling at various die gate shapes has been observed with the grain size controlled material. The effects of the gate shape on the die filling characteristics were investigated. The filling tests in each plunger strokes were experimented, also simulated on the semi-solid material die casting process by MAGMAsofi. According to the filling tests and computer simulation, the effect of the gate shape on liquid segregation had been investigated.

• Transactions of Materials Processing
• /
• v.14 no.1 s.73
• /
• pp.49-56
• /
• 2005

In the semi-solid die casting process, an important thing is the flow behavior of semi-solid materials. The flow patterns of the semi-solid material can make the defects during die filling. To control the flow patterns is very important and difficult. In this paper, the flow behavior of the semi-solid A356 alloy material during die filing at various die gate shapes has been observed with the grain size controlled material. The effect of the gate shape on the die filling characteristics was investigated. The filling tests in each plunger stroke were experimented, and also simulated on the semi-solid material die casting process by MAGMAsoft. According to the filling tests and computer simulation, the effect of the gate shape on liquid segregation has been investigated.

• Transactions of Materials Processing
• /
• v.10 no.5
• /
• pp.373-382
• /
• 2001

Die design by computer simulation has some advantages compared with the conventional method which has performed by designer's experiences and trials and errors. The die filling and solidification process of thixoforming process were simulated by MAGMAsoft/thixo module. Furthermore, the die design for thixoforming was performed with the various geometry shape. The effect of designed gate dimension on filling phenomenon was estimated by filling simulation. The calculated results was compared with experimental data. The free surface phenomenon obtained by experiment have good agreement with computer simulation results. The solidification effect much as prosity and shrinkage for designed semi-solid forging die had been predicted by computer simulation. The designed die for semi-solid forging had been applied to produce of the frame part which is used to airconditious system.

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

• Transactions of Materials Processing
• /
• v.5 no.3
• /
• pp.239-255
• /
• 1996

A new forming technology has been developed to fabricate near-net shape products using light metal. A semi-solid forming technology has some advantages compared with the conventional forming processes such as die casting squeeze casting and hot/cold forging. In this study the numerical analysis of semi-solid filling for a straight die shape and orifice die shape in gate pattern is studied on semi-solid materials(SSM) of solid fraction fs =30% in A356 aluminum alloy. The finite difference program of Navier-Stokes equation coupled with heat transfer and solidification has been developed to predict a filling pattern and the temperature distribution of SSM. The programdeveloped in this study gives die filling patterns of SSM and final solidifica-tion region.

• Transactions of Materials Processing
• /
• v.14 no.4 s.76
• /
• pp.351-359
• /
• 2005

The semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Also, the rheo-casting has been substituted for thixo-casting, because the rheo-casting can control the solid particles to globular and non-dendritic solid phase. In the rheo-casting process, the important thing is to control the solid particles behavior in semi-solid materials. So in this paper, to control solid particles behavior in semi-solid materials, we experimented about the die filling tests during the semi-solid die casting in 0.3, 0.4, 0.5 and 0, 6 solid fraction. The die filling in semi-solid die casting were simulated by MAGMA soft/thixo module. By the die filling tests and computer simulation, the effect of solid particles behavior in rheology flow had been investigated.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2002.05a
• /
• pp.769-773
• /
• 2002

The die easting process was used to manufacture a motor housing for automobile. Specially automobile parts were required light and high strength. Therefore simulations have been carried out die casting process of motor housing. In this paper, we investigated about characteristics of the die casted motor housing with HPDC(High Pressure Die Casting) process. Also the MAGMAsoft was used as computer simulation code and used material was ADC12(Aluminum Die Casting Alloy). We present the results of filling behavior and solidification process of a motor housing cast. The analysis results obtained about filling behavior and solidification of cast showed good agreement with test results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.10b
• /
• pp.152-157
• /
• 2003

A typical die-set for enclosed-die forging of half axle gears in double action hydraulic press is presented, the important factors those influence on precision forming of half axle gears are analyzed, warm forming process of half axle gears is simulated by FEM software $DEFORM\_3D$. The results show, that proper die structure and dimension, suitable web thickness and position can improve material filling, ensure full filling of tooth cavity.

• Design & Manufacturing
• /
• v.2 no.6
• /
• pp.33-37
• /
• 2008

Almost all injection molds have multi-cavity, which are designed with geometrically balanced runner system in order to made filling balance between cavity to cavity during injection molding. However, filling imbalance has been existed in the geometrically balanced runner system. In this study, we made an experiment and investigated that are filling balanced according to material. Also, in case of filling imbalance was occurred, we conducted experiments in order to find out difference of cavity pressure with cavity pressure sensor. When filling imbalance was occurred between cavity to cavity, we investigated the filling imbalance and pressure differences by computer-aided engineering(CAE).

• Design & Manufacturing
• /
• v.7 no.1
• /
• pp.19-22
• /
• 2013

Almost all injection molds have multi-cavity runner system for mass production, which are designed with geometrically balanced runner system in order to accomplish filling balance between cavity to cavity during processing. However, even though geometrically balanced runner is used, filling imbalances have been observed. So, many studies for improving filling balance in the multi-cavities molds are worked up. In this study, the Melt-Buffer which is a new runner system for filling balance has been suggested, and a series of experiment about degree of filling balance in cavity-to-cavity was conducted in the mold with the Melt-Buffer. From the experiment, the filling balance was increased up to 5~6% by using the Melt-Buffer.