CAE를 이용한 자동차용 부품(Gear Box)의 주조방안 설계에 대한 사례연구

Abstract

When manufacturing die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize casting design of an automobile part (Gear Box) Computer Aided Engineering (CAE)was performed by using the simulation software (Z􀙎Cast). The simulation results were analyzed and compared with experimental results. During the mold filling, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system. For making a better production die􀙎casting tool,cooling systems on several thick areas are proposed in order to reduce internal porosities caused by the solidification shrinkage.