• Title, Summary, Keyword: Metal Mold Casting

Search Result 111, Processing Time 0.122 seconds

Inverse Heat Transfer Analysis at the Mold/Casting Interface in the Aluminum Alloy Casting Process with Precision Metal Mold (정밀금형 알루미늄 합금주조공정시 주물/금형 접촉면에서의 Inverse 열전달해석에 관한 연구)

  • Moon, Su-Dong;Kang, Shin-Ill
    • Journal of Korea Foundry Society
    • /
    • v.18 no.3
    • /
    • pp.246-253
    • /
    • 1998
  • Precision metal mold casting process is a casting method manufacturing mechanical elements with high precision, having heavy/light alloys as casting materials and using permanent mold. To improve dimensional accuracy and the final mechanical properties of the castings, the solidification speed and the cooling rate of the casting should be controlled with the optimum mold cooling system, and moreover, to obtain more accurate control of the whole process interfacial heat transfer characteristic at the mold/casting interface must be studied in advance. In the present study, aluminum alloy casting system with metal mold equipped with electrical heating elements and water cooling system was designed and the temperature histories at points inside the metal mold were measured during the casting process. The heat transfer phenomena at the mold/casting interface was characterized by the heat flux between solidifying casting metal and metal mold, and the heat flux history was obtained using inverse heat conduction method. The effect of mold cooling condition upon the heat flux profile was examined, and the analysis shows that the heat flux value has its maximum at the beginning of the process.

  • PDF

Metal-Mold Reaction and Surface Roughness Measurement of Pure Titanium Casting Specimens with Mold Temperatures (순수 티타늄 주조체의 주형온도에 따른 용탕반응성 및 표면거칠기)

  • Cha, Sung-Soo;Song, Young-Ju;Park, Soo-Chul
    • The Journal of Korean Academy of Dental Technology
    • /
    • v.32 no.4
    • /
    • pp.297-305
    • /
    • 2010
  • Purpose: The purpose of this study was to observe the change of metal-mold reaction and surface roughness in titanium casting specimens for phosphate-silica alumina bonded investment with mold temperatures. Methods: The metal-phosphate silica alumina bonded mold interface reaction and surface roughness of titanium casting specimens according to mold temperatures were investigated. The Specimens were analysed by scanning electron microscopy and surface roughness tester. Results: The oxidation behavior indicated by the growth of oxide thickness. The titanium-oxide layer were consisted two layer of a porous external and a dense internal one. The reaction layer and surface roughness increased with increasing investment material temperature. Conclusion: In this work, The most suitable mold temperature in casting of pure titanium was $200^{\circ}C$.

Casting of Ductile Cast Iron using Metal Mold and Improvement of Impact Toughness by Direct Tempering (금형주조법에 의한 구상흑연주철의 제조 및 직접 템퍼링에 의한 충격인성 향상)

  • Choi, Sung Bae;Lee, Won Sik;Hong, Young Hwan
    • Journal of the Korean Society for Heat Treatment
    • /
    • v.10 no.3
    • /
    • pp.159-164
    • /
    • 1997
  • Non-alloyed and 1.0%Ni alloyed ductile cast iron were cast into the sand mold and metal mold, and finer graphite size was obtained in case of metal mold casting. Direct tempering after casting showed the slight increase of absorbed energy, which is largely due to the relieving of residual stress that is developed during casting. After austempering heat treatment, higher impact energy was obtained in case of metal mold casting than sand mold casting, which is due to the finer graphite size.

  • PDF

On the Measurement of Residual Stresses in Aluminum Alloy Parts Fabricated by Precision Metal Mold Casting (정밀금형 알루미늄 합금 주물에서의 잔류응력 측정에 관한 연구)

  • Kim, Chae-Hwan;Mun, Su-Dong;Gang, Sin-Il
    • Transactions of the Korean Society of Mechanical Engineers A
    • /
    • v.23 no.11
    • /
    • pp.2087-2095
    • /
    • 1999
  • One of the main causes of unwanted dimensional changes in precision metal mold casting parts is excessive and irregular residual stresses induced by temperature gradients and plastic deformation in the solidifying shell. Residual stresses can also cause stress cracking, and lower the fatigue life and fracture strength of the casting parts. In the present study, aluminum alloy casting system with metal mold equipped with electrical heating elements and water cooling units was designed and the casting specimens were produced to quantify the effects of different cooling conditions on the development of residual stresses. The layer removal method was used to measure the biaxial residual stresses in casting specimens produced from the experiments. The experimental results agreed with Tien-Richmond's theoretical model for thermal stress development for the solidifying metal plate.

Development of the Simulated Die Casting Process by using Rapid Prototyping (쾌속 조형 공정을 이용한 다이캐스팅 제품의 시작 공정 개발)

  • Kim K. D.;Yang D. Y.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
    • /
    • /
    • pp.180-186
    • /
    • 2002
  • The simulated die-casting process in which the traditional plaster casting process is combined with Rapid Prototyping technology is being used to produce Al, Mg, and Zn die-casting prototypes. Unlike in the die-casting process, molten metal in the conventional plaster casting process is fed via a gravity pour into a mold and the mold does not cool as quickly as a die-casting mold. The plaster castings have much larger and grosser grain structure as compared as the die-castings and the thin walls of the plaster mold cavity may not be completely fillet Because of lower mechanical properties induced by the large grain structure and incomplete Idling, the conventional plaster casting process is not suitable for the trial die-casting Process. In this work, an enhanced trial die-casting process has been developed in which molten metal in the plaster mold cavity is vibrated and pressurized simultaneously. Patterns for the casting are made by Rapid Prototyping technologies and then plaster molds, which have runner system, are made using these patterns. Imparted pressurized vibration to molten metal has made grain structure of castings much finer and improved fluidity of the molten metal enough to obtain complete filling at thin walls which can not be filled in the conventional plaster casting process.

  • PDF

Development of Sleeve Parts for Continuous Hot Zinc Plating Roll Applied to Wear-Resistant Alloy Cast Steel

  • Park, Dong-Hwan;Hong, Jin-Tae;Kwon, Hyuk-Hong
    • Journal of The Korean Society of Manufacturing Technology Engineers
    • /
    • v.26 no.4
    • /
    • pp.357-364
    • /
    • 2017
  • Metal casting is a process in which molten metal or liquid metal is poured into a mold made of sand, metal, or ceramic. The mold contains a cavity of the desired shape to form geometrically complex parts. The casting process is used to create complex shapes that are difficult to make using conventional manufacturing practices. For the optimal casting process design of sleeve parts, various analyses were performed in this study using commercial finite element analysis software. The simulation was focused on the behaviors of molten metal during the mold filling and solidification stages for the precision and sand casting products. This study developed high-life sleeve parts for the sink roll of continuous hot-dip galvanizing equipment by applying a wear-resistant alloy casting process.

Numerical and Experimental Studies on Thermal Strain Analysis of Al Alloy Casting Mold using Metal Foundry (금형주조기를 이용한 알루미늄 합금 금형의 수치해석적 열변형 해석과 실험에 관한 연구)

  • Oh, Yool-Kwon;Kim, Yong-Bum;Yoon, Hee-Sung
    • Proceedings of the KSME Conference
    • /
    • /
    • pp.2050-2054
    • /
    • 2007
  • This study numerically and experimentally investigated on thermal strain analysis of aluminum alloy casting mold using metal foundry. To predict the numerical result of thermal strain in Al alloy casting mold during the cooling process, it is performed the investigation of temperature distribution, stress and displacement based on the physical properties of Al alloy. In results of this study, Al alloy casting mold represented rapidly cooling graph during initial 20minutes after beginning cooling process, therefore value of stress and displacement is rapidly changed during initial 20minutes after beginning cooling process. In addition to, temperature distribution obtained by experiment confirmed corresponding pattern then compared numerical analysis with experiment. These results are distribute to make the effective and the high precision casting mold.

  • PDF

On the Measurment of Residual Stresses in Aluminum Alloy Casting Parts (알루미늄 합금 주조 부품에 발생하는 잔류응력의 측정)

  • 김채환
    • Proceedings of the Korean Society for Technology of Plasticity Conference
    • /
    • /
    • pp.102-106
    • /
    • 1999
  • One of the main causes of unwanted dimensional changes in precision metal mold casting parts is excessive and irregular residual stresses induced by temperature gradients and plastic deformation in the solidifying shell. Residual stresses can also cause stress cracking and lower the fatigue life and fracture strength of the casting parts,. In the present study aluminum alloy casting system with metal mold equipped with electrical heating elements and water cooling units was designed and the casting specimens were produced to quantify the effects of different cooling conditions on the development of residual stresses. the layer removal method was used to measure the biaxial residual stresses in casting specimens produced from the experiments. The experimental results agreed with Tien-Richmond's theoretical model for thermal stress development for the solidifying metal plate

  • PDF

3D scanning based mold correction for planar and cylindrical parts in aluminum die casting

  • Seno, Takashi;Ohtake, Yutaka;Kikuchi, Yuji;Saito, Noriaki;Suzuki, Hiromasa;Nagai, Yukie
    • Journal of Computational Design and Engineering
    • /
    • v.2 no.2
    • /
    • pp.96-104
    • /
    • 2015
  • Aluminum die casting is an important manufacturing process for mechanical components. Die casting is known to be more accurate than other types of casting; however, post-machining is usually necessary to achieve the required accuracy. The goal of this investigation is to develop machining- free aluminum die casting. Improvement of the accuracy of planar and cylindrical parts is expected by correcting metal molds. In the proposed method, the shape of cast aluminum made with the initial metal molds is measured by 3D scanning. The 3D scan data includes information about deformations that occur during casting. Therefore, it is possible to estimate the deformation and correction amounts by comparing 3D scan data with product computer-aided design (CAD) data. We corrected planar and cylindrical parts of the CAD data for the mold. In addition, we corrected the planar part of the metal mold using the corrected mold data. The effectiveness of the proposed method is demonstrated by evaluating the accuracy improvement of the cast aluminum made with the corrected mold.

Mold Material of Joseon Dynasty Period Movable Metal Types Produced by Investment Casting (인베스트먼트 주조법에 의해 제작된 조선시대 금속활자의 주형재료)

  • Park, Hak Soo;Yoon, Eui Pak
    • Korean Journal of Metals and Materials
    • /
    • v.48 no.6
    • /
    • pp.551-556
    • /
    • 2010
  • In this report, we describe mold materials that were used to produce movable metal type by the investment casting method during the Joseon dynasty period in Korea. Samples were obtained from the Wibuinja collection, which is held by the National Museum of Korea. Most of the mold material remnants were found in the depressed areas of the movable type specimens, and we therefore performed non-destructive analyses including XRF, EDS, and XRD. Through these analyses, we were able to identify the mold remnants as hydrocerussite [trilead dihydroxide dicarbonate, $Pb_3(CO_3)_2(OH)_2$] formed in platy hexagonal crystallites. Hydrocerussite was first used to make white pigments and cosmetics in ancient Greece, but this is the first report of hydrocerussite used as mold material applied around a disposable pattern for investment casting. The results of this study will further the understanding of the production process for early movable metal type and ancient casting technologies.