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조영석,박종배,한규택,정영득 한국공작기계학회 2002 한국공작기계학회 춘계학술대회논문집 Vol.2002 No.-
The die casting process was used to manufacture a alternator housing for automobile. Specially automobile parts were required light and high strength. Therefore simulations have been caned out die casting process of the alternator housing. In this paper, we investigated about characteristics of the die casted alternator housing with 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 results obtained about filling behavior and design of die of the cast showed good agreement with test results.
고압 다이캐스팅 공법을 이용한 마그네슘 시트프레임 개발
유명한(MyeongHan Yoo),문민석(MinSeok Moon),송준혁(JoonHyuk Song),오상엽(SangYeob Oh),오제하(JeHa Oh),양성모(SungMo Yang),강신재(SinJae Kang) 대한기계학회 2013 대한기계학회 춘추학술대회 Vol.2013 No.12
In this study, the express bus seat-frame components were substituted by the Mg alloy from the steel for the light weight. Mg alloy seat-frame was manufactured by the high pressure die-casting process. The designs of the existing steel alloy’s seat-frame were analyzed to check the safety requirements, and then were designed for a high pressure die-casting process with considering the fluidity of Mg alloy. The die-casting conditions were decided with the solidification and fluidity analysis, and die-casting mold was made with this results. Normally, the seat-frame was consisted of arm-rest and seat-back-frame. To confirm the Mg seat-frame safety, it was that mechanical property, vertical load, and forward moment, and endurance fatigue were simulated and tested. Finally, the light-weight Mg alloy seat-frame was made by high pressure die-casting with the seat-back-frame 35% weight-reduction and the arm-rest 30% weight-reduction compare to the steel alloy seat-frame.
고압 다이케스팅 공정을 이용한 대형 트럭 현가장치용 알루미늄 V-arm 개발
문민석,송준혁,유명한,노종일,오제하,양성모,문상돈 한국기계기술학회 2018 한국기계기술학회지 Vol.20 No.3
The investigation on the lightweight of automobiles has been underway in commercial vehicles as well as passenger cars due to global warming and strengthening of European emission standards. In this study, the V-arm were developed for lightweight parts using aluminum alloy instead of steel with high pressure die casting processing. This study has focused on lightweight adaptive concept design. Several models of V-arm were designed and analyzed for the fluidity and solidification. V-arm was produced with ADC12 by high pressure die-casting process. The mechanical properties of developed V-arm were measured; such as tensile strength, elongation, shear strength, and durability. The possibility of mass production with the light weight aluminum V-arm substitute from the steel. The weight was reduced about 38% from 16kg to 9.98kg. The productivity was improved with decreasing the process from 8 to 5 by All-in-0ne process using high pressure die-casting.
자동차용 Heatsink의 열전도도 향상을 위한 다이캐스팅 알루미늄 합금 및 열처리 최적 조건 개발
김주행(Juhaing Kim),정경(Kyung Jeong),박석현(Seokhyun Park),정윤철(Yooncheol Jung) 한국자동차공학회 2018 한국자동차공학회 부문종합 학술대회 Vol.2018 No.6
As eco-friendly automobiles are expanded, electronic control systems are also required to have high performance. Therefore, ECUs and motors, which are essential for electronic control systems, require higher heat dissipation characteristics than conventional ones. In order to achieve high heat dissipation characteristics, it is necessary to improve the thermal conductivity of Heatsink itself, which is directly contacts the heat source and transfers heat quickly among various components. As the conventional Heatsink materials, aluminum alloys which have excellent thermal conductivity characteristics have been applied. In case of low-solute alloy, the thermal conductivity is the highest. However, in the case of automotive Heatsink, a very complicated shape is required, and in order to realize this, it is necessary to manufacture parts by die casting of a high-solute aluminum alloy. As a result, it has lower thermal conductivity than low solute aluminum alloy. In this study, the optimum alloy composition capable of high pressure casting with 7% Si content and T5 heat treatment were applied to achieve thermal conductivity of 178W/mK. This result is a high thermal conductivity characteristic of low-solute wrought aluminum alloy products, resulting in a 38% improvement over ADC12, a commercial die-cast alloy. At the same time, heatsinks for large-capacity motors(BSG) were developed by securing the same castability as ADC12.
Effect of grain size on residual stress in AlSi10MnMg alloy
전민정,이은경 한국마린엔지니어링학회 2023 한국마린엔지니어링학회지 Vol.47 No.4
The effect of varying the grain size on the residual stress in AlSi10MnMg alloys prepared at various cooling rates was examined. The specimens with different initial grain sizes were manufactured by high-pressure die casting (HPDC) and gravity die casting (GDC) under heat treatment at 500 °C for 2 h, followed by furnace cooling and water quenching to control the variables that could affect the residual stress or induce microstructural changes. The average grain size of the non-heat-treated as-cast HPDC speci-men was approximately 30 times smaller than that of the as-cast GDC specimen, and the residual stress of the large-grain GDC speci-men was approximately 20 MPa larger. The grain size of the furnace-cooled GDC specimen was approximately 50 times larger than the average grain size of the furnace-cooled HPDC specimen, and the largest difference in the residual stress was approximately 40 MPa. The average grain sizes of the water-quenched GDC and HPDC specimens differed by approximately ten-fold, where the residual stress in the water-quenched GDC specimen was approximately 8 MPa higher. The larger the grain size, the more easily the low-angle grain boundaries are penetrated by the potential. Therefore, a larger the grain size leads to better distribution of the low-angle grain systems; thus, numerous dislocations were distributed inside and around the grain. The grain boundaries and dislocations that were highly aggregated inside the grain influenced the residual stress.
고압 다이캐스팅 Al-6Si계 합금의 인장특성 및 열전도성에 미치는 Ni과 Cu 첨가 영향
장재철,신광선 대한금속·재료학회 2020 대한금속·재료학회지 Vol.58 No.4
In this study, the effects of nickel and copper on the mechanical and thermal properties of Al-Si alloys were investigated, for different alloy compositions. Thermodynamic calculations were carried out to predict the alloys’ solidification behavior (solidification temperature, solid fraction and physical properties (density, thermal conductivity, elastic modulus, bulk modulus)). The aluminum alloys were produced by high pressure die-casting process with a 125 ton die-casting machine. Microstructures in the Al-Si-Ni alloys were characterized by optical microscopy and scanning electron microscopy. The mechanical properties were evaluated by tensile tests. Thermal conductivity was measured using a laser flash method. The addition of Ni and Cu improved the mechanical properties of the alloys by different strengthening mechanisms. Solution strengthening was the more effective method of improving mechanical properties, compared with strengthening by intermetallic compounds. The addition of an appropriate concentration of soluble alloying elements consistently improved alloy strength. However, addition of alloying elements decreased the thermal conductivity of the primary alpha aluminum phase. EDS analysis confirmed that soluble alloying elements like Cu not only can form intermetallic compounds, but can also change other kinds of compounds. Accordingly, careful consideration should be given to the chemical composition of soluble/insoluble alloying elements when attempting to improve mechanical properties and thermal conductivity at the same time.
Metallurgical Assessment of Novel Mg–Sn–La Alloys Produced by High‑Pressure Die Casting
Azim Gökçe 대한금속·재료학회 2020 METALS AND MATERIALS International Vol.26 No.7
Mg alloys containing Al are widely used for industrial applications, but the use of these alloys as an automotive part is limiteddue to the low melting temperature of the Mg17Al12intermetallic phase. Therefore, magnesium alloys without aluminumthat can withstand higher operating temperatures are of interest to the automotive industry. The objective of this work is todevelop Al-free Mg alloys for industrial applications. In the current work, four types of alloys were produced with varyingLa contents. The high-pressure die casting method was selected to overcome the problems inherent in the gravity castingmethod with respect to the production of parts with complex shapes and thin walls. X-ray diffraction analysis revealed thatthe base alloy (Mg–5Sn wt%) comprises of α-Mg and Mg2Snphases whereas La containing alloys included intermetallicphases such as LaMg3,Mg17La2,and La5Sn3. Corresponding grain sizes of the alloys with La are lower than those of theMg5Sn alloy. Due to this lower grain size and emerging dispersoids, the tensile strength of the Mg5Sn4La alloy (205 MPa)is roughly double that of Mg5Sn. Moreover, the addition of the 4% wt. La to the Mg5Sn alloys led to an increase in yieldstrength and ductility by 25% and 50%, respectively.
파이프 인서트 기술을 적용한 알루미늄 고압주조 부품개발
강문구(MunGu Kang),윤형섭(HyungSop Yoon),이철웅(CheolUng Lee),임태성(TaeSeong Lim),김성진(SeongJin Kim),윤광민(KwangMin Yoon) 한국자동차공학회 2022 한국 자동차공학회논문집 Vol.30 No.1
Recently, shaped components, from which oil or cooling water flows, have been produced. In order to fabricate the components produced by the High-Pressure Die-Casting(HPDC) process, such as oil-path, the deep hole-drilling method has been applied. However, it causes problems like oil leaks or cooling water leaks because HPDC products have plenty of defects, such as shrinkage or large pores. In this investigation, the pipe-inserted aluminum rear cover component was fabricated by HPDC. Instead of conducting hole-drilling on the rear cover, a pipe was inserted on the mold before casting during HPDC. Hence, defect exposure by post-machining was fundamentally blocked. A theoretical formula was derived in which the inserted pipe of the HPDC component was not deformed under a certain intensification pressure of HPDC, since there is a relationship between the HPDC processing parameter and the mechanical properties of the inserted pipe. Based on the theoretical formula, the relationship between the HPDC parameter and pipe deformation was proved in the experiment.