• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.126-129
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• 1998

Proper design of blocker dies is one of the most important aspect of impression and closed-die forging to achieve adequate metal distribution. Determination of the blocker configuration is a very difficult task and is art in itself, requiring skills achieved only by years of extensive experience. To save the cost and time of blocker design, many methods using computer were proposed. In this research, low pass filter method proposed by Oh etc. was applied to blocker die design of spoiler support, part of aircraft and plasticine model experiment of closed die forging of spoiler support was accomplished to verify the validity of the blocker designed.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.3
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• pp.42-52
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• 1995

An UBET(Upper Bound Elemental Techniquel) program has been developed to analyze forging load, die-cavity filling and effective strain distribution for flashless non-axisymmetric forging. To analyze the process easily, it is suggested that the deforma- tion is divided into two different parts. Those are axisymmetric part in corner and plane- strain part in lateral. The total power consumption is minimized through combination of two deformation parts by building block method, form which the upper-bound forging load, the flow pattern, the grid pattern, the velocity distribution and the effective strain are deter- mined. To show the merit of flashless forging, the results of flashless and flash-forging processes are compared through theory and experiment. Experiments have been carried out with plasticine billets at room temperature. The theoretical predictions of the forging load and the flow pattern are in good agrement with the experimental results.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 1999.04a
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• pp.26-26
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• 1999

가장 오래된 금속성형법 중의 하나인 열간 단조는 재결정온도-고상선(강재의 경우, 일반적으로는 1,200-l,28$0^{\circ}C$)의 온도로 재료를 가열하여 간단한 형상의 소재로부터 하나 또는 둘 이상의 공정을 통하여 최종제품을 생산해내는 소성가공법이며, 이것은 절삭 가공에 비하여 재료의 손실이 적으며, 생산속도가 빠르고 또한 단류선(flow line)의 방향으로 인장강도, 충격강도 등의 기계적 강도가 커야 할 필요가 있는 제품의 대량 생산에 적합한 가공법이다.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.4 no.1
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• pp.36-41
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• 2003

The purpose of this study was to find a way to lengthen the life of hot closed forging die. The fluid interpretation on the plastic deformation of billet of billet was performed by finite element method. And design modification on the impression shape was also performed. The defaced part on the impression surface was mended by the developed build-up welding method. The die life was 3,000 units but alter the procedure it was lengthened up to 5,000.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.1029-1032
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• 2001

The purpose of this paper is to establish an automated die design system for compacting and sizing process required in Powder Metallurgy. Though the Powder Metallurgy(P/M) is a practical and economical forming technology, it needs long time and many trials and errors for die design. Such a problem can be solved by introduction of the automated die design system for P/M. In order to establish the system, collecting, classifying, and systematizing related knowledges from the experts in industries, books, and papers were performed. The system was constructed by AutoLISP, the language operated in AutoCAD atmosphere. This language can efficiently support for user to work on drawings. There are three modules ; P/M part specification input module, P/M part design module, and Die design module. A part for vehicle was applied to the system and satisfied results were achieved.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.10a
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• pp.164-167
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• 1997

The die wear is one of the main factors affecting die accuracy and tool lifetime. It is desired to reduce die wear by developing simulation method to predict wear based on process parameters, and then optimize the process. Therefore, this paper describes disign methodology of preform for minimizing wear of finisher die in multi-stage cold forging processes. The finite element method is combined with the routine of wear prediction and the cold forging processes. The finite element method is combined with the routine of wear prediction and the cold forging process is analyzed. In order to obtain preform to minimize die wear, the FPS algorithm is applied and the optimal preform shape is found from iterative deformation analysis and wear calculation.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.6
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• pp.3692-3697
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• 2015

A screw is a type of fastener characterized by a helical ridge known as thread. The demands for screws with the miniaturization and weight reduction are increasing for the trend of small size of mobile devices. The successful designs of mold and process are very important to obtain screws with good mechanical properties and high precision. In this study, the design of cold forging process of micro screw was carried out by using finite element method. In particular, in order to investigate the effects of die geometries and friction, design of experiment method was adopted and it was revealed that the friction was the dominant factor of folding defects. From these results, the design of die was modified and experiments were carried out with the modified die. From the experimental results, it was found that the folding defects disappeared.

• Transactions of the Korean Society of Mechanical Engineers
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• v.16 no.11
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• pp.2082-2089
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• 1992

An experimental study on forging an axi-symmetric dome type of AISI4130 was carried out using modeling material. In order to verify the validity of the experimental data, a similarity study between plasticine and AISI4130 has been made. Friction conditions were characterized by ring test for the various lubricants. For the closed-die forging experiments of an axi-symmetric dome type of AISI4130 using the plasticine, various cylindrical billets with different aspect ratios were forged and different flash width to thickness(W/T) ratios were used in order to determine the optimum forging conditions. As W/T ratios decrease forging loads decrease while excess volumes increase. It was found out that the experimental results reproduce the similiar results available in the literature. As a result of these experiments, it was construed physical modeling is an excellent tool for forging process simulation at a practical level.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.12
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• pp.8-15
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• 2021

Cold forging is a method in which molding is performed at room temperature. It has a high material recovery rate and dimensional precision and produces excellent surface quality, and it is mainly used for the production of bolted or housing products. The lifespan of cold forging molds is generally determined by the wear of the mold, plastic deformation of the mold, and fatigue strength. Cold forging molds are frequently damaged due to fatigue destruction rather than wear and plastic deformation in a high-temperature environment as it is molded at room temperature without preheating the raw material and mold. Based on the results analyzed through FEM, an effective mold structure design method was proposed by analyzing the changes in tensile and compressive stresses on molds according to the number of molds and reinforcement rings and comparing the product geometry and mold stress using three existing mold models.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.4
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• pp.653-659
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• 2017

In this study, the complex forging process of an outer support ring was developed and the prototype was manufactured. The current process, hot forging and MCT machining, has a disadvantage of excessive material removal rates and longer machining hours. To overcome this disadvantage, a general shape is given through hot forging and the precision is achieved through cold forging. The complex forging process was developed with the minimal machining process. Forging analysis was carried out to design a forging process using the commercial program, Deform-3D. The hot and cold forging processes were set up based on the analyzed result. The mold and prototype were manufactured. Hardness, surface roughness, internal defect, the grain low line of the prototype were evaluated. The results showed no particular problems, and there were no problems in mass production. Using complex forging, the material was reduced by approximately 27 % compared to the process using hot forging and MCT machining. In addition, the production speed was improved 2.15 fold compared to that of hot forging and MCT machining. Through this study, a cost-effective process and mold design technology were established, which is expected to have positive effects on other related automotive parts production.