Valves are one of the indispensable components in modern industry. Filling and de-pressure connectors in rocket valves used for space launch vehicles are very important parts for smooth fluid supply. For this reason, an optimized design that can improve efficiency, miniaturization, weight reduction, and safety of the valve at the same time is required. In this work, flow analysis and structural analysis were performed through 3D modeling using computational numerical analysis for open type filling and de-pressure valves. As results, the flow velocity and pressure distribution of the fluid were analyzed through the flow analysis of valve, and stress distribution was conducted in structural analysis. Through this study, it is consequently expected to provide valves of various specifications by performing production and performance test evaluation of development prototypes.

In turbopump type liquid rocket engines, ignition and starting are known to be the most unstable and risky section among all operating sections of the projectile. The operation of the liquid rocket engine is the process of ignition and combustion of the main combustor after the turbo pump is driven into a stable section due to the turbine driving of the turbo pump and the ignition and combustion of the gas generator by the pyro starter. In this process, the driving of related components directly influences each other, so each component must be operated with sufficient reliability. In particular, if the igniter does not supply sufficient ignition energy at a predetermined time, an explosion may occur due to stagnation of the fuel/oxidant mixture, so reliability is more important. In this study, the fracture analysis of the gas generator igniter rupture disk according to the shape was performed using computational analysis. As a result, comparative analysis was performed to obtain the optimal dimensions according to each variable condition.

A most important progress in civilization was the introduction of mass production. One of main methods for mass production is die-casting molds. Due to the high velocity of the liquid metal, aluminum die-casting is so complex where flow momentum is critical matter in the mold filling process. Actually in complex parts, it is almost impossible to calculate the exact mold filling performance with using experimental knowledge. To manufacture the lightweight automobile bodies, aluminum die-castings play a definitive role in the automotive part industry. Due to this condition in the design procedure, the simulation is becoming more important. Simulation can make a casting system optimal and also elevate the casting quality with less experiment. The most advantage of using simulation programs is the time and cost saving of the casting layout design. For a 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 the casting layout design of an automotive Oil Pan_BR2E, Computer Aided Engineering (CAE) simulation was performed with three layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process with three models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflows. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

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 optimizing casting layout design of an automobile part (Oil Pan_DX2E) Computer Aided Engineering (CAE) simulation was performed with two layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the mold filling with two models, internal porosities caused by air entrap were predicted and also compared 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 also compared by the modification of the gate system.