• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.7 no.4
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• pp.50-55
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• 1998

Mould level control system for continuous casting process involves stick-slip friction in the sliding gate , time-delay, non-linearity, and certain uncertainties such as friction force variations between molten steel and the inner wall of mould. In this paper, sliding mode control technique was used to solve these complex control problem. The controller is then designed and implemented onto the continuous casting process. Testing result shows that sliding mode controller can decrease the fluctuating magnitude of the mould level and is superior to the existing PID controller.

• Journal of Korea Foundry Society
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• v.11 no.1
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• pp.79-84
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• 1991

The process of solidification of metal is accompanied by liquid-solid change and known as Stefan's heat conduction problem on the moving boundary. In this study the temperature distribution in ingot and metallic mould during casting was analyzed by the two dimensional heat conduction theory. The transient temperature distribution was numerically calculated using a finite element method on the nodal point of mesh screen representing ingot and mould cross section. The theory was applied on the casting of aluminum(purity ; 99%) in flat ingot mould of GC25. The analysis will make it possible to calculate an optimum mould shape of which temperature gradient becomes minimum.

• Journal of Korea Foundry Society
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• v.11 no.3
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• pp.245-253
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• 1991

It is known that the analysis of thermal stresses is substantially important in optimal design of casting mould. In this paper unsteady state thermal stresses generated in ingot and mould during the solidification process are analyzed by the two dimensional thermal elasto-plastic analysis. Distribution of temperature and stress of the mould is calculated using the finite element method and compared with experimental result. The significant results obtained in this study are as follows. At the early stage of the casting process, abrupt temperature change was shown in the vicinity of the inner surface of the mould. The largest temperature gradient is occurred at the corner of the mould. In the thermal stress analysis, compressible stress occurred in the inside wall of the mould where as tensile stress on outside wall. Smaller thermal stress is observed at the rounded corner. It is also observed that the shown is influenced by the thickness of the wall. A fairly good coincidence is found between analytical and experimental results, showing that the proposed analytical methodology is reliable.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2002.05a
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• pp.387-392
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• 2002

A portable mould oscillation analyzer with an integrated computer, developed by POSCO, records the movement of the mould in every spatial direction. The system uses the gap sensors to measure the mould movement (displacement) in two horizontal directions according to the mould narrow and broad faces and the vertical strokes in the four corners of mould. The gap sensor is a non-contacting minute displacement-measuring device using the principle of high frequency eddy current loss. The mould oscillation diagnostic system integrates the gap sensors, their converters and the industrial portable computer with plug-in data acquisition boards. In an own expert module, which is included in the diagnosis program, one can obtain much information about the mould oscillation equipment.

• Journal of Conservation Science
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• v.28 no.4
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• pp.417-425
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• 2012

Bronze Mirror with fine linear designs in the bronze age shows the greatest alloy and casting skills of the day and presents the highest level of handcrafting and molding techniques. Lately, Lost-wax casting and sand-mould casting were used for the restoration of the national treasures of No. 141 and No. 143 Bronze Mirror with fine linear designs. Also the Principle Component Analysis, Microstructure Analysis, X-ray and SEM-EDS analysis were carried out on the restored Bronze Mirror with fine linear designs. Bronze Mirror that is made of sand-mould casting, hardly has a eutectoid and it is observed as a ${\alpha}$ dendrite. In contrast, Bronze Mirror that is made of lost-wax casting, the eutectoid has found through the ${\alpha}$ dendrite. As we compare lost-wax casting to the sand-mould casting through an analysis of restored Bronze Mirror, mostly, sand-mould casting has better castability and it seems that it brings a clear and equal Bronze Mirror as it has a low cooling rate. In this way, we are able to confirm that there is a big difference between the method by lost-wax casting and by sand-mould casting through an analysis of microstructure and restored Bronze Mirror. If such research will be continued, it will be an opportunity that investigates diverse methods of production techniques.

• Journal of Korea Foundry Society
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• v.13 no.1
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• pp.81-93
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• 1993

It is well-known that the analysis of elasto-plastic thermal stress and deformation are substantially important in optimal design of metal casting mould. The unsteady state thermal stress and deformation generated during the solidification process of ingot and mould have been analyzed by two dimensional thermal elasto-plastic theories. Distributions of temperature, stress and relative displacement of the mould are calculated by the finite element method and compared with experimental results. In the elasto-plastic thermal stress analysis, compressive stress occurred at the inside wall of the mould whereas tensile stress occurred at outside wall. A coincidence between the analytical and experimental results is found to be fairly good, showing that the proposed analytical method is reliable.

• Transactions of Materials Processing
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• v.18 no.2
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• pp.135-143
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• 2009

In the casting industry field, a lot of researches have been carried out to maximize soundness and productivity and improve quality of mass produced products. The researches on the optimum mould design by using computer simulation have achieved a lot of accomplishments in the die-casting process especially. Their results are utilized to mass-produce sound products in their field. But there are some difficulties to use the simulation in order to make the design of product and mould. In general, repetitive calculations of computer simulation require much analyzing time in order to make sound design of them. Another difficulty is that only expertise technicians can analyze results of the simulation. In order to solve such a problem, we are building mould design optimization system which consists of knowledge-based module, simulation, optimization module and interactive modeler(it is based on the commercial modeler). By using and interacting between these modules of that system, we can easily make an optimum design of mould and construct the database. This study introduce the general process of the system and connection method between the modules is mentioned above and some examples to apply it to real product.

• Journal of Korea Foundry Society
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• v.15 no.3
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• pp.291-297
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• 1995

The mechanical properties and fracture toughness of permanent mold cast austempered gray cast iron(AGI) were compared to those of sand cast AGI. The iron was melted to eutectic composition in order to get better castability especially in permanent mold casting. Specimens prepared for tensile, impact and fracture toughness test were austenitized at $900^{\circ}C$ and austempered at $270^{\circ}C$ and $370^{\circ}C$ for 1 hour. The strength, impact and fracture toughness of permanent mold cast AGI were found to be superior to those of sand cast AGI. The maximum value of 836 MPA in tensile strength, was obtained at the austempering temperature of $270^{\circ}C$. But ductility of AGI was not improved by permanent mold casting.

• Metals and materials international
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• v.24 no.6
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• pp.1315-1326
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• 2018

In this work, ultrasonic vibration (UV) and rheo-squeeze casting was first applied on the Mg alloy reinforced with long period stacking ordered (LPSO) structure. The semisolid slurry of Mg-Zn-Y alloy was prepared by UV and processed by rheosqueeze casting in succession. The effects of UV, Zr addition and squeeze pressure on microstructure of semisolid Mg-Zn-Y alloy were studied. The results revealed that the synergic effect of UV and Zr addition generated a finer microstructure than either one alone when preparing the slurries. Rheo-squeeze casting could significantly refine the LPSO structure and ${\alpha}-Mg$ matrix in $Mg_{96.9}Zn_1Y_2Zr_{0.1}$ alloy without changing the phase compositions or the type of LPSO structure. When the squeeze pressure increased from 0 to 400 MPa, the block LPSO structure was completely eliminated and the average thickness of LPSO structure decreased from 9.8 to $4.3{\mu}m$. Under 400 MPa squeeze pressure, the tensile strength and elongation of the rheocast $Mg_{96.9}Zn_1Y_2Zr_{0.1}$ alloy reached the maximum values, which were 234 MPa and 17.6%, respectively, due to its fine ${\alpha}-Mg$ matrix (${\alpha}1-Mg$ and ${\alpha}2-Mg$ grains) and LPSO structure.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.3
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• pp.485-496
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• 1992

본 연구에서는 제철, 제강공정에서 많이 사용하고 있는 C22FR1.4형의 주형을 상사적으로 축소시킨 주철제(GC25) 주형에 순알루미늄(순도99%)의 주물을 용입하여 응고 및 냉각 과정의 주물 및 주철제 주형에 미치는 열의 영향에 관하여 2차원 비정상 열전도 문제를 경계요소법으로 해석하고 실험을 통하여 검증하였다.