• Journal of Korea Foundry Society
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• v.24 no.1
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• pp.3-9
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• 2004

Die casting is "a process in which molten metal is injected at high velocity and pressure into a mold(die) cavity". Casting with smooth surfaces, high dimensional precision, complicated shapes, and reduced weight can be obtained using this process. But this process is susceptible to casting defects such as porosities, scattered chilled layers, hard spots, etc. For preventing casting defects, we developed "low-velocity high pressure die casting technology", "squeeze die casting technology", "heat insulating sleeve lubricant technology", and "direct pouring technology". The "direct pouring technology" is useful for producing molten metal without oxide contamination. It consists of a pumping system which supplies pure molten metal to the die casting machine. By using this technology, we have successfully reduced oxide contamination in castings to 1/20 of that of our previous castings.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.04a
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• pp.3-7
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• 2002

The die casting process was used to manufacture a alternator housing for automobile. Specially automobile parts were required light and hight strength. Therefore simulation have been carried out die casting process of the alternator housing. In this paper, we investigated about characteristics of the die casted alternator housing the 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 result obtained about filling behavior and design of die of the cast showed good agreement with test result.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.769-773
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• 2002

The die easting process was used to manufacture a motor housing for automobile. Specially automobile parts were required light and high strength. Therefore simulations have been carried out die casting process of motor housing. In this paper, we investigated about characteristics of the die casted motor housing with HPDC(High Pressure Die Casting) process. Also the MAGMAsoft was used as computer simulation code and used material was ADC12(Aluminum Die Casting Alloy). We present the results of filling behavior and solidification process of a motor housing cast. The analysis results obtained about filling behavior and solidification of cast showed good agreement with test results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.435-436
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• 2009

In the effort on cost reduction in marine equipment company, the medium sized impeller blade ($500mm{\times}200mm{\times}20mm$) of an axial flow pan was manufactured by the high pressure die casting, with which was replaced the gravity die casting. High pressure die casting is a practical alternative because of some advantages such as excellent accuracy and smooth cast surface as well as cost reduction if a certain amount of porosity in the parts can be minimized. In order to reduce the porosity in the center of the neck which is thickest region of the impeller blade, the several gate designs were proposed in this work. The flow simulations for each gate design were performed and then the optimal design was determined by considering the air pressure distribution in neck section. Finally, the size of porosity in the neck of the die cast impeller blade for optimal design was less than 1mm, which satisfied the requirement.

• Journal of Korea Foundry Society
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• v.41 no.6
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• pp.521-527
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• 2021

This study presents a process management method for the detection of casting defects during in high-pressure die casting based on machine learning. The model predicts the defects of the next cycle by extracting the features appearing over the previous cycles. For design of the gearbox, the proposed model detects shrinkage defects with data from three cycles in advance with 98.9% accuracy and 96.8% recall rates.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06b
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• pp.60-66
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• 1998

The horizontal cold chamber pressure die casting produces a variety of net shape, complicate-geometry castings with desired mechanical properties. dimensional tolerance, and surface finish. However, top quality castings can be achieved only when optimal performance of thecold chamber (shot sleeve )and plunger is maintained druing the molten metla injection phase of the process. Unforturately, inreality , shot sleeves deteriorate fast and sometimes fail catastrophically due to incorrect design. These early and unexpected failures of shot sleeves cost die casters money and productiivity. To prevent promature failures of shoe sleeves major faulure mechanisms were investigated. with the aid of analyticla solutions robust design criteria for shot sleeves have been developed. The data directly obtained from failed shot sleeves in the die casting industry for automotive parts, support a strong correlation between design and filures. by applying these design criterial we expected premature faulures of shot sleeves can be avoided in die casting industry.

• Journal of Korea Foundry Society
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• v.32 no.3
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• pp.133-137
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• 2012

Chill vent has a zigzag venting path which allows residual air or gases to exhaust out very quickly from the die cavity. However molten metal sometimes comes out through the gas venting surfaces causing flash. Effect of designing factors of chill vent and processing variables in high pressure die casting on the performance of chill vent was investigated through a series of calculations by using a commercial code. The most influential factor was the thickness of chill vent, followed by inlet velocity, vent width and die temperature.

• Journal of Korea Foundry Society
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• v.32 no.1
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• pp.16-23
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• 2012

In this study, we develop the lower pressure die casting with rheo-forming process of A356 aluminum alloy and vacuum system which can control the crystal size and obtain the high strengthened-light material. Using this process, we fabricate the thin plate for bipolar plate through the low pressure die casting with electromagnetic stirring and vacuum-evacuation which can control the crystal grain by electromagnetic stirring. Thin plate ($110mm{\times}130mm{\times}1mm$) is fabricated by this process. The average Vickers hardness of thin plate is about 77 HV.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.3
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• pp.88-97
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• 2009

The vacuum die casting techniques can diminish the porosity of products and provide better surface appearance by the ordinary high pressure die casting process. The vacuum system can also reduce the cold laps in the die casting process and minimize the overflow pockets of the die. The vacuum system does not need high pressures to die cast compared to the ordinary die casting process, and so enables die casting of large parts for a given machine size. Parts made by the vacuum system have higher strength and more elongation than parts made by the ordinary die casting systems. In this paper, we designed and produced the Magnesium seat frames using the vacuum die casting processes. The new Magnesium seat frame was designed to satisfy safety regulations. Some safety test procedures of the seat frame were simulated by the finite element method. We obtained 10% weight reduction by design modification of seat frames compared to the current model. Flow simulations were carried out to minimize the trial and error in producing the parts. The die casted parts using vacuum systems resulted in better mechanical characteristics and no defects compared to those without vacuum systems.

• Korean Journal of Materials Research
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• v.16 no.8
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• pp.516-523
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• 2006

In recent years, Magnesium (Mg) and its alloys have become a center of special interest in the automobile industry. Due to their high specific mechanical properties, they offer a significant weight saving potential in modern vehicle constructions. Most Mg alloys show very good machinability and processability, and even the most complicated die-casting parts can be easily produced. The die casting process is a fast production method capable of a high degree of automation for which certain Mg alloys are ideally suited. In this study, step-dies and flowability tests for AM50 were performed by die-casting process according to various combination of casting pressure and plunger velocity. We were discussed to velocity effect of forming conditions followed by results of microstructure, FESEM-EDX, hardness and tensile strength. Experimental results represented that the conditions of complete filling measured die-casting pressure 400 bar, 1st plunger velocity 1.0 m/s and 2nd plunger velocity 6.0 m/s. The increasing of 2nd plunger velocity 4.0 to 7.0 m/s decreased average grain size of $\alpha$ phase and pore. It was due to rapid filling of molten metal, increasing of cooling rate and pressure followed by increased 2nd plunger velocity. The pressure should maintain until complete solidification to make castings of good quality, however, the cracks were appeared at pressure 800bar over.