주조해석을 통한 Mg Armrest Frame 최적 공정 설계에 관한 연구

다국어 초록 (Multilingual Abstract)

Demands for improved fuel consumption efficiency is increasing due to the recent strengthened environmental regulation in the developed nation, which are aimed to meet abnormal climate change due to the global warming and the depletion of natural resources. Now the ways to improve fuel efficiency has been proposed as a lightweight way.
That lighter cars was using the lightweight materials such as replacing existing materials, how to improve the strength and toughness it.
Aluminum alloy has been popularized the lightweight material in recent years. But magnesium alloys was increasing to the pursuit of high-performance and energy-saving purpose of the machine. The reason that magnesium alloys is lighter than aluminum alloy with specific gravity of 1.74, aluminum (specific gravity 2.70) more than 35 percent lighter. Magnesium also has excellent strength and bending modulus of the automotive and recently have been used in the aircraft parts. The method of cast magnesium had been used to die-casting process. Through die-casting process, the magnesium production weight is decreasing compared with the steel part.
Recently, through the die-casting process, only small part of car produce production. And the die-casting process conditions has a lot of impact on the environment. So study of the die-casting process for large products is insignificant.
In this paper, the last goal is using the die-casting process that the armrest frame of inner part of commercial buses design the optimal process with the use of lighter material magnesium alloy. Molding conditions set up the most good effect it, the optimal process design of the die-casting process was designed by kind of 18 design of experiments with response surface method(RSM).
The optimum casting conditions selected using Design Of Experiment(DOE) and casting analysis is performed. Applied to the process, comparing the results of each experiment conditions and optimum value was found to produce a product. And the product was produced by optimal design. With the products, the X-Ray Inspection tests and three-dimensional measurement were performed. The result of tests is consistent with the analysis results.

목차 (Table of Contents)

• 목 차 i
• Abstract iii
• List of tables vii
• List of figures ix
• 제 1 장. 서 론 1
• 1-1. 연구배경 1
• 1-2. 연구동향 4
• 1-3. 연구목적 및 내용 7
• 제 2 장. 이론적 배경 9
• 2-1. 마그네슘 및 마그네슘 합금의 특성 9
• 2-2. Armrest Frame의 개요 15
• 2-3. 다이캐스팅 공법 17
• 2-4. 최적화설계 이론 19
• 2-5. 유동성 이론 23
• 제 3 장. 실험 방법 29
• 3-1. 주조방안 설계 29
• 3-2. 실험계획법 설계 35
• 제 4 장. 유동해석 결과 분석 및 고찰 37
• 4-1. 실험계획법 결과 분석 및 고찰 37
• 4-2. 최적화 모델 해석 분석 및 고찰 59
• 4-3. 열변형 해석 분석 및 고찰 64
• 제 5 장. 주조 및 시험 평가 66
• 5-1. X-Ray 평가 66
• 5-2. 3차원 측정기 평가 70
• 제 6 장. 결론 73
• 참고문헌 75
• 감사의 글 77