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아연 합금 웜기어의 중력 주조 공정을 위한 주조 방안 설계 및 해석에 관한 연구
이운길 ( Un-gil Lee ),김재현 ( Jae-hyun Kim ),진철규 ( Chul-kyu Jin ),천현욱 ( Hyeon-uk Chun ) 한국산업융합학회 2021 한국산업융합학회 논문집 Vol.24 No.5
In this study, the optimum gating system was designed, and the two zinc alloy worm gears were manufactured in single process by applying a symmetrical gating system with 2 runners. The SRG ratio is set to 1 : 0.9 : 0.6, and the cross-sectional shapes such as sprue, runner and gate are designed. In order to determine whether the design of the gating system is appropriate, casting analysis was carried out. It takes 4.380 s to charge the casting 100%, 0.55 to 0.6 m/s at the gates and solidification begins after the casting is fully charged. The amount of air entrapment is 2% in the left gear and 6% in the right gear. Hot spots occurred in the center hole of the gear, and pores were found to occur around the upper part of the hole. Therefore, the design of the casting method is suitable for worm gears. CT analysis showed that all parts of worm gear were distributed with fine pores and some coarse pores were distributed around the central hole of worm gear. The yield strength and tensile strength were 220 MPa, 285 MPa, and the elongation rate was 8%. Vickers hardness is 82 HV.
전차 파워팩에 적용되는 알루미늄 터보 팬의 주조방안 설계 및 주조 해석에 관한 연구
진철규,이운길,Jin, Chul-Kyu,Lee, Un-Gil 한국산업융합학회 2022 한국산업융합학회 논문집 Vol.25 No.5
In this study, sand casting process was applied to manufacture a large aluminum turbo-type fan used for tank powerpack. To apply the sand casting method, the turbo fan was reverse engineered, and after designing three gating systems, the optimal gating system design was selected by performing casting simulation. In the case of the bottom up-gating system, there is a significant temperature loss of the molten alloy during blade filling. When the molten alloy is completely filled into the sand mold, the blade upper tip and front shroud are below the liquidus temperature. In the case of the top down-gating system, molten alloy scattering occurs, but the temperature loss while the blade is filled is smaller than that of the bottom up type. And after the inflow of molten alloy into the mold is completed, the blade upper tip and front shroud are higher than the liquidus temperature. A sand mold was manufactured with the top down-gating system and the casting process was performed. The fan was made perfectly in appearance without any unfilled parts.
터보 팬의 유동해석 및 허니콤 구조가 적용된 터보 팬의 PBF 3D 프린팅 제작에 관한 연구
진철규,이해수,이운길,우재혁,Jin, Chul-Kyu,Lee, Haesoo,Lee, Un-Gil,Woo, Jae-Hyeog 한국산업융합학회 2022 한국산업융합학회 논문집 Vol.25 No.5
In this study, a study was conducted to localize a large aluminum turbo fan used for tank powerpack. The turbo fan was scanned with a 3D scanner and then 3D modeling was performed. Computational fluid dynamics (CFD) were performed from the performance conditions of the fan, and structural analysis was performed using the pressure data obtained from CFD. The fan was reduced to 1/5 size by applying the geometric similarity. A 1/5 size fan has a honeycomb structure inserted into the front shroud and back shroud to reduce the weight by 5.3%. A 1/5 size fan was printed using a PBF 3D printer, and a 1/5 size fan with honeycombs was also printed. The pressure drop of 8.67 kPa and the required power of 138.19 kW, which satisfies the performance conditions of the fan, were confirmed from the results of CFD. The values of the maximum deformation amount of 0.000788 mm and the maximum effective stress of 0.241 MPa were confirmed from the structural analysis results. The fan printed by the PBF 3D printer had the same shape as the modeling, and the shape was perfect. There are no defects anywhere in appearance. However, the condition of the outer surface of the fan's back shroud is rough compared to other locations. The fan in which the honeycomb was inserted was also perfectly output, and the shape of the honeycomb was the same as the modeling.