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자동차용 LPG 연료 탱크 밸브의 다이캐스팅 방안의 유동해석
배성호,김상철,김희수 한국주조공학회 2022 한국주조공학회지 Vol.42 No.6
In this study, we investigated the casting designs for fuel tank valves for LPG automobiles. The valves we studied have two cav-ities inside the part. There is inevitable air entrapment inside the cavities. In order to reduce this kind of casting defect, we carriedout computer simulations of molten metal flow during the diecasting process of the target products. The main process parameterswere the ingate position, product direction, and injection velocity. We also examined the possible use of vacuum diecasting. Theposition of the air entrapment was almost identical for all the ingate positions and product directions. We found that the change ofthe injection velocity affects the position of the air entrapment. In case of vacuum diecasting, the position of the air entrapment wassimilar to the previous cases, but it is expected that the air entrapment will be highly reduced in a real situation due to the vac-uumed space. 본 연구에서는 LPG 자동차용 연료탱크 밸브 제조를 위한 주조방안에 대하여 연구하였다 . 대상 밸브에는 그 내부에 두 개의돌기가 존재한다 . 돌기 내부에는 기공 결함이 흔히 발생하였다 . 이러한 주조 불량을 최소화하기 위하여 대상 제품의 다이캐스팅 과정에서 용탕 흐름에 대한 컴퓨터 시뮬레이션을 수행하였다 . 주요 공정 매개변수는 인게이트 위치 , 제품 방향 및 주입 속도였다 . 또한 진공 다이캐스팅의 사용을 고려하였다 . 기공 결함의 위치는 모든 인게이트 위치와 제품 방향에 대해 거의 동일했다 . 한편 주입속도의 변화가 공기 포획의 위치에 영향을 미친다는 것을 알 수 있었다 . 진공 다이캐스팅의 경우 기공 결함의 위치는 이전의 경우와 비슷했지만, 실제 상황에서는 진공으로 인해 기포가 많이 줄어들 것으로 예상된다.
자동차용 Seat Motor Housing의 부품 일체화에 관한 연구
이동욱(Tong Uk Lee),김병각(Byung Gak Kim),김인관(In Kwan Kim),김영수(Young Soo Kim) 한국자동차공학회 2006 한국자동차공학회 춘 추계 학술대회 논문집 Vol.- No.-
The general way of cost reduction in automobiles was focused on the substitute the material from combination to parts composites. The main research is focused on the substitutive design of Seat Motor Housing, with materials by the hot chamber diecasting process with zinc alloy diecasting. The newly developed parts were compared with the original products. The diecasting process was used to manufacture a Seat Motor Housing for automobile. Seat Motor Housing was modelled with UNI GRAPHICS that analyze with Z-CAST software. Z-CAST was computer software with FDM(finite difference method). The analysis results obtained about filling behavior and solidification of casting showed good agreement with test results. New product was evaluation of the performance. In result, Diecasting of Seat Motor Housing is expected to be best fitted in Works.
다이캐스팅 ADC12 합금의 열처리 전후의 기계적 특성변화
강신욱 ( Shin-wook Kang ),박경섭 ( Kyeong-seob Park ),오은호 ( Eun-ho Oh ),심정일 ( Jung-il Shim ),김희수 ( Hee-soo Kim ) 한국주조공학회 2016 한국주조공학회지 Vol.36 No.3
We investigated the effect of heat treatment on an ADC12 alloy produced using diecasting. The heat treatment used in this study was a typical T6 process: a solid solution treatment followed by an artificial aging treatment. As-cast specimens were solid-solution-treated at 500oC and 530oC for 1-16 hr, and aged at 160oC and 180oC for 1-8 hr. Microstructural changes in the alloy during the heat treatment were observed. Changes in mechanical properties of the alloy were measured using a micro Vickers hardness tester. Finally, we determined the optimal heat treatment conditions for the diecast ADC12 alloy.
대형 산업용 전동기 회전자용 알루미늄 다이캐스팅의 주조성을 고려한 슬롯 형상 설계 기준 정립
이성모 ( Sung Mo Lee ),김덕수 ( Deok Su Kim ),박태동 ( Tae Dong Park ),윤영철 ( Young Cheol Yoon ) 한국주조공학회 2016 한국주조공학회지 Vol.36 No.1
Numerical analysis has been performed to evaluate effect of the shape variables such as core length, slot width and slot length on misrun in aluminum die casting process for motor rotor. The predictive method for misrun in diecasting process was established by comparing the result of numerical analysis and an actual motor rotor. Solidification modulus was introduced to predict quantitatively the castability of aluminum diecasting process for motor rotor. It was found that there are minimum critical solidification modulus and slot width to prevent misrun according to core length through diecasting limit diagram proposed using the predictive method. The critical solidification modulus and slot width increase as core length increases to prevent misrun of aluminum motor rotor in diecasting process. Based on the results, the design criteria of slot shape to prevent misrun of aluminum motor rotor with various core length were established.
Kang, C.G.,Seo, P.K.,Jeon, Y.P. Elsevier 2005 Journal of materials processing technology Vol.160 No.1
<P><B>Abstract</B></P><P>The reheating conditions to the thixo diecasting process of wrought alloys were given as the control of reheating time and temperature. The reheating process to obtain of a globurized microstructure is performed by various heating step of repeatedly heating process with various temperature steps. The solid fraction and the mean diameter of the semi-solid material after the reheating process are measured by the image analysis. The various problems in fabricating thin wall component by the thixo diecasting process have been investigated with a wrought aluminum alloy. In order to investigate filling phenomena during the thixo diecasting process, the die for the fabrication of the thin-type component was used for this study. In the thixo diecasting process for wrought alloys, the cause of the internal defect phenomenon and microstructure are shown with experimental data.</P>
Sim, J. G.,Choi, B. H.,Jang, Y. S.,Kim, J. M.,Hong, C. P. The Iron and Steel Institute of Japan 2010 ISIJ international Vol.50 No.8
<P>A new slurry-making method, called the nucleation-accelerated semi-solid slurry (NASS) method, was developed to fabricate high-quality semi-solid slurry with fine and uniform globular microstructures. The method's application to rheo-diecasting of ADC10 alloy was investigated. To enhance the heterogeneous nucleation of primary α particles in the initial stage of solidification, various types of funnels, including the pouring system in the slurry-making vessels, were designed and estimated by thermal analysis. It was found that the heterogeneous nucleation of primary α particles was closely related to the temperature–time history and the flow pattern. In the present study, the NASS method was set up based on the optimized funnel. It consisted of a specially designed conical-shaped funnel and the electromagnetic stirring (EMS) unit for artificial agitation. The conical-shaped funnel generated swirly flow pattern in the melt. This was further exaggerated by the EMS in the slurry-making vessel during the pouring stage, resulting in a copious heterogeneous nucleation. The qualities of the slurry were investigated using optical microscopy and rheo-diecasting. To study the effect of process parameters, the semi-solid slurry of ADC10 alloy was rheo-diecast using an 85-ton high-pressure die casting (HPDC) machine. Microstructural observation and hardness test were then carried out on the rheo-diecast specimens. The rheo-diecast products of the NASS method showed fine and uniform microstructures, with primary α-globules diameter averaging 39 μm and form-factor indicating a degree of globularity of 0.9. The optimized heat treatment condition for the rheo-diecast product of ADC10 alloy was achieved at the solution temperature of 490°C for 30–60 min, water quenching, and age hardening at 180°C for 7–8 h.</P>
다이캐스팅에서 용탕 유동 해석을 통한 결함 감소에 관한 연구
오창복(Changbok Oh),조태홍(Taehong Cho),박종수(Jongsoo Park),박정권(Jungkwon Park),이호길(Hokil Lee) 한국자동차공학회 2011 한국자동차공학회 학술대회 및 전시회 Vol.2011 No.11
This study reviewed the optimized manner of a diecasting part to reduce casting detects such as porosities. Molten metal in sleeve was analyzed for the selection of an intended diecasting machine and 2 phase, molten metal and air, in cavity was calculated. In order to prevent molten metal from mixing with air by vortex and initially defective molten metal, fill rate, low and high speed injection must be determined by the grade of the diecasting machine. As known widely, it is verified that overflow or air-vent must be located at the confluence of molten metal and the sudden change in the direction of molten metal affects flow status. Mold needs to determine design through analysis for molten metal flow.
박규섭 ( Kyu Sup Park ),장영수 ( Young Soo Jang ),최병희 ( Byoung Hee Choi ),강병근 ( Byung Kuen Kang ),김해수 ( Hae Soo Kim ),최상호 ( Sang Ho Choi ),홍준표 ( Chun Pyo Hong ) 한국주조공학회 2012 한국주조공학회지 Vol.32 No.2
Recently, development of Al-based alloys for high mechanical performance has been an important issue in automotive industry. The present study focused on the design of a high strength Al-based alloy for rheo-diecasting. The research was based on thermodynamic calculation and experimentals to optimize the alloy compositions. Two important considerations were carried out: i) to obtain uniform slurry with fine and globular microstructures for rheo-diecasting, ii) to be strengthend by T6 heat treatment. In order to evaluate the effect of Si content on the slurry microstructure and castability, thermodynamic calculation and fluidity test were carried out. The effects of various alloying components, such as Mg, Cu and Zn, on age hardenability were also investigated. The mechanical properties of the rheo-diecasting products using the newly developed alloy are 324MPa in tensile strength, 289MPa in yield strength, and 11.2% in elongation after T6 heat treatment.
A Study on the Design of Gating System for Semi-Solid Diecasting Process
Park, Chul-Woo,Kim, Young-Ho Korean Society for Precision Engineering 2003 International Journal of the Korean Society of Pre Vol.4 No.2
In the Semi-Solid Diecasters design, a Seni-Solid Diecasters experiment has usually been carried out before producing new casts. At the Semi-Solid Diecasting stages, the runner-gate part has been always repeatedly corrected, which leads to a tedious processing time and high processing cost. Much experience is essential in manual assessment and if the design is defective, much time and a great deal of efforts will be wasted in the modification of the die. In this study, a design system has been developed based on the design database In addition, a gate experiment for the gating system design has been tarried out to append the database. It is possible for engineers to make efficient gating system design of Semi-Solid Diecasting and it will result in the reduction of expenses and time to be required.
A356 합금의 중력 주조/단조와 Rheo-diecasting/단조의 미세조직 및 기계적 특성 비교
이준영 ( Jun Young Lee ),임재용 ( Jae Yong Lim ),이승용 ( Seung Yong Lee ),문성원 ( Seoug Won Moon ),홍준표 ( Chun Pyo Hong ) 한국주조공학회 2013 한국주조공학회지 Vol.33 No.5
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.