• Transactions of the Korean Society of Mechanical Engineers B
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• v.24 no.1
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• pp.102-113
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• 2000

In this study, a three-dimensional gravity casting problem has been examined to investigate a coupled phenomenon of the filling and solidification process. This work simultaneously considers the two key phenomena of metal casting : the fluid flow during mold filling, and solidification process. The VOF method is used to analyze the free surface flow during filling and the equivalent specific heat method is employed to model the latent heat release during solidification. The time-implicit filling algorithm is applied to save the computational time for analyzing the mold filling process. The three-dimensional benchmark problem used in the MCWASP VII has been solved using both the implicit and explicit algorithm, and the present results are compared with the benchmark experimental results and the other numerical results.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.5 no.2
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• pp.27-35
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• 2006

Al used in automobiles is mostly material, and according to the innovation of technique is in rapid development. Al die casting is an important field as today's trend of lightweight on automobiles. Valve housing in steering system improves driver's controling. The valve housing which is widely reliable to the most automobiles are developed this moment in our automobile industry. Therefore, they are produced by casting method which cost three times or even more expensive in production. If valve housing which is a part of steering system is produced by gravity casting, the space for manufacturing equipment will be increased, and more time and workers would be brought into service. For such reason, die casting would replace gravity casting in order to minimize cost of time, manpower, and working space. This study is the forming analysis of the 2 cavity die casting for automobile valve housing.

• Design & Manufacturing
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• v.15 no.2
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• pp.30-35
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• 2021

The casting method uses a mold to solidify a liquid metal to make a solid metal. Since it uses a liquid metal with the least deformation resistance, it has the characteristic that it can easily manufacture even a complex shape. However, the process of solidifying a liquid metal into a solid metal inevitably involves a volume change and contains internal defects such as shrinkage holes. Therefore, in the design of the casting plan, an excess volume called a pressurization compensates for the volume shrinkage. in the product, and it induces the shrinkage hole defects to occur in parts other than the product1). In this study, casting analysis was performed using casting analysis software (anycasting) in order to optimize the design of the tilting gravity casting method for automobile brackets. In particular, the filling and solidification analysis according to the shape and volume of the pressurized metal was conducted, and applied to the actual product to study the effect of the pressurized metal on the shrinkage defect. Through this study, it is possible to understand the effect of the pressure metal on shrinkage defects in the actual product and propose a design of the pressure metal that improves reliability and productivity.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.902-905
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• 2000

As the manufacturing processes of automotive engine piston, gravity die-casting, squeeze casting, hot forging and powder forging process are generally used for the various specifications. As the semi-solid forming(SSF) is compared with conventional casting such as gravity die-casting and squeeze casting for the characteristics of its process, the product without inner defects such as gas porosity and segregation can be obtained and its microstructure is globular grain. In SSF process, the materials are heated up to the temperature between the solvus and liquidus line at which the materials exists in the form of liquid-solid mixture. In this time, Discussion is given about reheating process of row material and results are presented regarding accurate temperature and process variables controlling for right solid fractions.

• Journal of Korea Foundry Society
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• v.33 no.5
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• pp.210-214
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• 2013

Recently, the automotive industry has replaced cast iron to lightweight materials like aluminum for engine efficiency of automobiles and an emission control by government. In this paper we studied two auto parts manufacturing methods using an alloy of A356. That is gravity casting and H-NCM Rheo-diecasting forging. We analyzed the microstructure and mechanical properties for this method. In Microstructure analysis results, H-NCM Rheo-diecasting forging has more finer microstrucre and better forging effect. Resulting in better mechanical properties than gravity forging.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.8
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• pp.1709-1718
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• 2002

It is well recognized that improving capacity of positive grid in battery is one of key factors for controlling the expected long lift-time of Battery Energy Storage System(B.E.S.S). Thus it is really important to characterized material properties of positive grid which are mainly affected by fabrication process. In this study, two kinds of positive grids, which were fabricated by gravity casting and die-casting technique were used. Micro-structural observation and tensile test were conducted to investigate the effect of fabrication process of positive grid. Ultrasonic measurement based on pulse-echo method and ultrasonic C-scan technique also performed to correlate ultrasonic velocity with porosity ratio in positive grid. It was found that the porosity ratio of grid fabricated by gravity casting technique increased significantly compared to the grid fabricated by die-casting technique. It was also shown that ulrasonic technique is effective to evaluate the porosity ratio in positive grid.

• Journal of Korea Foundry Society
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• v.9 no.1
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• pp.39-48
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• 1989

A basic three dimensional thermal model has been developed to simulate the solidification sequence for gravity die casting process. The finite difference method was used to analyze the solidification process during all the casting cycles. The prediction of die temperature in the quasi-steady state was analyzed by the boundary element method. The influence of die cooling on the heat flow in the cast/mold system was also investigated. Predictions of the computer simulation on temperature profiles and location of shrinkage defects were in good agreement with those observed in experimental die castings. Models of computer simulation which is developed by this work can be useful for the design and process control of die casting.

• Proceedings of the KWS Conference
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• 2003.11a
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• pp.207-209
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• 2003

In FE analysis for residual stress of a casting, contact force between mould and casting material and gravity force must be considered for exact simulation. Preheating of a repair weldment had a little effects on the reduction of residual stress. However, preheating with hammer peening had a great deal of effects on the reduction of residual stress. A method for estimation of fatigue life for a repair weldment has been established.

• Journal of Korea Foundry Society
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• v.38 no.6
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• pp.111-120
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• 2018

In this study, the effects of two different casting methods (gravity casting and, diecasting) and various solid-solution conditions on the mechanical properties of ASC (Al-10.5wt%Si-1.75wt%Cu) and ALDC12 (Al-10.3wt%Si-1.72wt%Cu-0.76wt%Fe-0.28wt% Mn-0.32wt%Mg-0.9wt%Zn) alloys were investigated. A thermodynamic solidification analysis program (PANDAT) was used to predict the liquidus, solidus, and phases of the used alloys. In the results of an XRD analysis, ${\beta}$-AlFeSi peaks were observed only in the ALDC12 alloy regardless of the casting method or SST (solid-solution treatment) conditions. However, according to the results of a FE-SEM observation, both ${\theta}(Al_2Cu)$ and ${\beta}$-AlFeSi were found to exist besides ${\alpha}$-Al and eutectic Si in the gravity-casted ASC alloy at $500^{\circ}C$ after a SST of 120min. The ${\alpha}$-AlFeSi and ${\beta}$-AlFeSi phases including the eutectic phases were also found to exist in the ALDC12 alloy. The results of a microstructural observation and analyses by XRD, FE-SEM and EDS were in good agreement with the PANDAT results. The gravity-casted ALDC12 and ASC specimens showed the highest Y.S. and UTS values after aging for three hours at $180^{\circ}C$ after a SST at $500^{\circ}C$ for 30min. At longer solid-solution treatment times at $500^{\circ}C$ in the gravity-casted ALDC12 and ASC specimens, the elongations of the ASC alloys increased, whereas they decreased slightly in the ALDC12 alloys.

• Journal of Korea Foundry Society
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• v.17 no.4
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• pp.385-392
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• 1997

The main objective of this study is to investigate the microstructure and tensile strength of $SiC_p$/Al alloy composites fabricated by die casting method. Die casting was performed using the preheated mold at the pouring temperature range of $620{\sim}750^{\circ}C$ under the pressure of $1,039 kgf/cm^2$. The low speed and a following high injection speed were 0.4 and 2.1 m/s, respectively. The microstructure of $SiC_p$/Al alloy composites fabricated by die casting method was found to be finer than that of composites fabricated by gravity casting. Also, SiC particulates were homogeneously distributed in refined Al matrix due to rapid solidification. The tensile strength of $SiC_p$/Al alloy composites fabricated by die casting method was found to be varied with cast temperature. The maximun tensile strength of $SiC_p$(10 vol.% and 20 vol.%)/Al alloy composites showed 380 MPa at the cast temperature of $750^{\circ}C$ and 363 MPa at the cast temperature of $700^{\circ}C$, respectively.