When manufacturing die casting mold, generally, the casting layout design should be considered based on the relation between 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 optimizing 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.

1. 서론
 2. 해석방법
  2.1 전산해석 과정
  2.2 해석조건
  2.3 해석내용
 3. 해석결과
  3.1 충진해석결과
  3.2 응고해석 결과
 4. 실험결과 및 비교
  4.1 금형모델링 및 제작
  4.2 결과비교 및 고찰
 5. 결론
 참고문헌

• Moo-Kyung Jang(Dept. of Industrial and Management Engineering, Namseoul University) | 장무경
• Hongkyu Kwon(Dept. of Industrial and Management Engineering, Namseoul University) | 권홍규