• Title/Summary/Keyword: 자유형단조

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Study on Manufacturing Process of Hollow Main Shaft by Open Die Forging (자유단조공법을 통한 중공형 메인샤프트 제조공정에 관한 연구)

  • Kwon, Yong Chul;Kang, Jong Hun;Kim, Sang Sik
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.40 no.2
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    • pp.221-227
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    • 2016
  • The main shaft is one of the key components connecting the rotor hub and gear box of a wind power generator. Typically, main shafts are manufactured by open die forging method. However, the main shaft for large MW class wind generators is designed to be hollow in order to reduce the weight. Additionally, the main shafts are manufactured by a casting process. This study aims to develop a manufacturing process for hollow main shafts by the open die forging method. The design of a forging process for a solid main shaft and hollow shaft was prepared by an open die forging process design scheme. Finite element analyses were performed to obtain the flow stress by a hot compression test at different temperature and strain rates. The control parameters of each forging process, such as temperature and effective strain, were obtained and compared to predict the suitability of the hollow main shaft forging process. Finally, high productivity reflecting material utilization ratio, internal quality, shape, and dimension was verified by the prototypes manufactured by the proposed forging process for hollow main shafts.

Analysis of Free Forging of Cylindrical Billets by Using finite Element Method (유한요소법을 이용한 원통형 강편의 자유단조 해석)

  • 정동원
    • Journal of Ocean Engineering and Technology
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    • v.16 no.6
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    • pp.49-54
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    • 2002
  • The Finite Element Method is applied to the determination of the deformed bulge profile and strain distribution during upset forming of cylindrical billets. From the results of simulation, the bulging along the z-axis becomes more severe with increasing eight reduction, and with increasing friction at the die-material interface. The present method can be used for the simple prediction of the deformed shape and strain distribution in upset forging of cylindrical billets with dissimilar fictional conditions at the die-material interfaces.

The Incipient Deformation Analysis for Plane Strain Open-Die Forging Processes with V-shaped Dies Using the Force Balance Method (힘평형법을 이용한 V-형다이 평면변형 자유형 단조공정의 초기변형 해석)

  • Lee, J.H.;Kim, B.M.
    • Journal of the Korean Society for Precision Engineering
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    • v.10 no.4
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    • pp.109-117
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    • 1993
  • Force balance method is employed to predict forging information such as forging load, tool pressure and normal stress at the surface of tangential velocity discontinuity. The incipient stages of deformation for the plane strain forging of rectangular billets in V-shaped dies of different semi-angles are analysed. To construct an approximate model for the analysis of deformation by the force balance method in the incipient deformation stages, slip-line field is used. When the deformation mode by slip-line method is the same as that by force balance method, the slip-line method and the force balance method give identical solutions. The effects of die angle, coefficient of friction, billet geometries and deforma- tion characteristics are also investigated. In order to verify the validity of force balance analysis, the rigid-plastic finite element simulation for the various forgig parameters are performed and performed and find to be in good agreement.

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Forging process design of cup shaped large forging using finite element method (유한요소해석을 통한 컵형상 대형단조품의 성형공법 설계)

  • Kang, Jong Hun;Kim, Hyun Jun;Lee, Hyoung Woo
    • Journal of Advanced Marine Engineering and Technology
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    • v.39 no.7
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    • pp.729-734
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    • 2015
  • This research developed a new deep-bore, cup-shape, large forging process by combining die forging and free forging methods. In the proposed process, a preform for cup-shape large forging is produced by die forging, and a product with a deep bore is finally manufactured using an open die forging method, which is generally produced using a backward extrusion process. Finite element analysis results showed a higher effective strain distribution with a smaller forging load using the proposed method compared to the backward extrusion method. The production of a prototype with good internal quality using a small press capacity verified the proposed method.

Investigation of the Forging Process of Exhaust Valve for Large Diesel Engine (대형 디젤엔진용 배기밸브의 단조공정에 관한 연구)

  • Kim, Dong-Kwon;Kim, Dong-Young;Suk, Jhin-Ik;Ryu, Seog-Hyeon;Kim, Dong-Jin;Kim, Byung-Hoon
    • Proceedings of the KSME Conference
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    • 2001.06c
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    • pp.627-632
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    • 2001
  • Nimonic 80A superalloy with high-temperature strength and high corrosion-resistance is used in jet engine for aircraft, gas turbine for power plant and marine diesel engine, etc. To develop the manufacturing process of exhaust valve for large diesel engine using Nimonic 80A, various mechanical tests, such as hot compression, microstructure and hardness test have been performed. This results effectively used to set the reasonable forging conditions while hot forging of Nimonic 80A superalloy. Open die and closed die forging experiments are carried out from ESR ingot and finally get a good shaped exhaust valve product.

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UBET Analysis of Combined Forging of Non-Axisymmetric Shapes With Inclined Protrusion (경사진 돌출부가 있는 비축대칭 복합단조의 상계요소해석)

  • 윤정호;양동열
    • Transactions of the Korean Society of Mechanical Engineers
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    • v.14 no.1
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    • pp.1-12
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    • 1990
  • The study is concerned with the analysis of combined forging of non-axisymmetric shapes with inclined protrusions by UBET technique. Work hardening is considered for the given range of strain rate during the forging process. A complex shape with inclined cavities is analyzed by subdividing the workpiece into finite UBET elements for which simple velocity fields are applicable. An experimental set-up was designed and manufactured for the experiment, and experiments are carried out with lead billets. The devised set-up can be used for closed-die forging of complex shapes with protrusions in which the dies can be separated automatically for easy removal of the forged products. Based on the derived kinematically admissible velocity fields for corresponding UBET elements, general computer programs have been developed. Since the energy dissipation rate for each elemental region is provided by subprograms (Subroutine or Function), the developed program can be applied to the forging problems of various shapes. The present study has shown that the method developed can be effectively applied to forging of non-axisymmetric shapes with complicated protrusions.

Comparative Study on Pore Closing in Open Die Forging by Conventional Forging Press and Radial Forging Machine (일반자유단조 프레스와 방사형 단조 프레스의 기공 압착에 관한 비교 연구)

  • Kim, S.H.;Lee, M.C.;Jang, S.M.;Eom, J.G.;Joun, M.S.
    • Transactions of Materials Processing
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    • v.19 no.7
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    • pp.399-404
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    • 2010
  • We propose an analysis model for simulating the detailed procedure of pore closing in open die forging of shafts. In the analysis model, an artificial symmetric plane is used, on which initial pores are located to be traced. The analysis model is employed to carry out three-dimensional simulation of pore closing in shaft free forging by both conventional free forging press and radial forging machine. With this result, two typical types of free forging equipment for manufacture of shafts are compared in detail. It has shown that the radial forging machine is much superior to the conventional open die forging press especially in pore closing under high hydrostatic pressure with sound strain.

Manufacturing Process of the Ti-6Al-4V Billet by the Open-die Forging (자유형 단조 공정에 의한 Ti-6Al-4V 빌렛 제조기술)

  • Kim, K.J.;Choi, S.S.;Hwang, C.Y.;Kim, J.S.;Yeom, J.T.;Lee, J.S.
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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    • 2006.05a
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    • pp.377-380
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    • 2006
  • Manufacturing process of Ti-6Al-4V alloy billet was investigated with FEM simulation and experimental analysis. Before the breakdown process of Ti-6Al-4V alloy ingot, FEM simulation for the breakdown processes of Ti-6Al-4V alloy ingot was used to calculate the forging load and state variables such as strain, strain rate and temperature. In order to breakdown the ingot structure and make an equiaxed structure billet, two different processes were employed for a VAR/VAR processed Ti-6Al-4V alloy ingot. Firstly, the ingot was cogged in single-phase $\beta$ field at the temperature of $1,100^{\circ}C$. In the process, the coarse and inhomogeneous structure developed by the double melting process was broken down. The second breakdown was performed by upsetting and cogging processes in $\alpha+\beta$ phase field to obtain the microstructure of fine equixed $\alpha$ structure in the matrix of transformed $\beta$. Finally, the mechanical properties of Ti-6Al-4V alloy billet made in this work were compared with those of other billet and ring product.

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Formation of the $2^{nd}$ Phases in Spray Cast Al-25Si-(Fe,V) Alloy (분무주조 A1-25Si-(Fe,V) 합금에서의 2 차상 형성거동)

  • 박우진;이언식;안상호
    • Proceedings of the Korean Powder Metallurgy Institute Conference
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    • 2000.04a
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    • pp.16-16
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    • 2000
  • 분무주조법으로 제조된 Al-25Si-(Fe,V) 합금빌렛의 미세조직을 광학현미경, 주사전자현미경, 투과전자현미경으로 분석하였으며, 빌렛내에서 관찰되는 2차상의 형성거동을 정확히 분석하기 위해 over-sprayed 분말의 미세조직을 분무주조 빌렛과 함께 관찰하였다. 먼저 분무주조 빌렛을 표면으로부터 중심부까지 관찰한 결과, 분무주조 빌렛의 미세조직은 표면부 10mm 가량을 제외하고는 매우 균일한 미세조직을 보여주었다. 이에 본 연구에서는 분무주조 빌렛의 표면부와 중심부, 그리고 over-sprayed 분말조직으로 구분하여 각각에서 관찰되는 2차상을 관찰하였으며, 이를 바탕으로 분무주조 빌렛내에 형성된 2차상의 형성기구를 규명하고자 하였다. Over-sprayed 분말의 미세조직은 기지조직내에 균일하게 분포된 침상의 $\delta$-AlFeSi 상과 각형의 Si 입자로 구성되어 있었다. 반면, 분무주조 빌렛의 경우, 그 중심부에서는 기자조직내에 균일하게 분포된 막대형의 $\beta$-AlFeSi과 부정형의 조대한 Si입자가 관찰되었으며, 표면부에서는 부정형의 Si 입자와 함께 막대형의 $\beta$-AlFeSi/$\delta$-AlFeSi 복합상이 관찰되었다. 특히, 빌렛 표면부의 $\beta$-AlFeSi 상과 $\delta$-AlFeSi 상간에는 일정한 방위관계가 존재하였으며, 이러한 결과는 분무주조 빌렛내에 분포된 $\beta$-AlFeSi상들이 분무액적내에 형성된 준안정 $\delta$-AlFeSi 상으로부터 상분해되어 형성되었음을 제시한다. 이상의 분무주조 조직과 over-sprayed 분말의 미세조직으로부터 분무주조 빌렛의 최종 주조조직은 반응고상태의 분무액적 조직에 의해 지배됨을 알 수 있다.r plate)의 단면 미세조직 사진으로써 모재부와 오버레이충을 함께 보여주고 있다. 모재와 오버레이 충간의 경계면은 모재 일부가 용융된 후 웅고하면서 형성됨으로 인해서 도금이나 용사층과는 달리 매우 견고하게 결합되어 있다. 따라서 계면부의 탈락이라는 문 제점은 거의 없어 심한 응력을 받는 기계구조물 및 부품에도 본 기술은 널리 적용되고 있다. 그리고 사진 1에서 알 수 있는 바와 같이 모재와는 전혀 상이한 재료를 자유로이 선택하여 표면 유효층 일부만 오버레이시키며I 주조 및 단조가 불가능한 재료까지도 표면부에 오버레이 시킴으로 서 부품 및 설비의 제조에 있어 재료비의 절감과 제품의 수명이 획기적으로 개선될 수 있다. 그리고 최근에는 도금 빛 용사 둥과 같은 표면처리를 할 경우임의 소재 표면에 도금 및 용 사에 용이한 재료를 오버레이용접시킨 후 표면처리를 함으로써 보다 고품질의 표면층을 얻기위한 시도가 이루어지고 있다. 따라서 국내, 외의 오버레이 용접기술의 적용현황 및 대표적인 적용사례, 오버레이 용접기술 및 용접재료의 개발현황 둥을 중심으로 살펴봄으로서 아직 국내에서는 널리 알려지지 않은 본 기 술의 활용을 넓이고자 한다. within minimum time from beginning of the shutdown.및 12.36%, $101{\sim}200$일의 경우 12.78% 및 12.44%, 201일 이상의 경우 13.17% 및 11.30%로 201일 이상의 유기의 경우에만 대조구와 삭제 구간에 유의적인(p<0.05) 차이를 나타내었다.는 담수(淡水)에서 10%o의 해수(海水)로 이주된지 14일(日) 이후에 신장(腎臟)에서 수축된 것으로 나타났다. 30%o의 해수(海水)에 적응(適應)된 틸라피아의 평균 신사구체(腎絲球體)의 면적은 담수(淡水)에 적응된 개체의 면적보다 유의성있게 나타났다. 해수(海水)에 적응(適應)된 틸라피아의 신단위(腎單位)의 사

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Development of 3-D Nonlinear Wave Driver Using SPH (SPH을 활용한 3차원 비선형 파랑모형 개발)

  • Cho, Yong Jun;Kim, Gweon Soo
    • KSCE Journal of Civil and Environmental Engineering Research
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    • v.28 no.5B
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    • pp.559-573
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    • 2008
  • In this study, we newly proposed 3-D nonlinear wave driver utilizing the Navier-Stokes Eq. the numerical integration of which is carried out using SPH (Smoothed Particle Hydrodynamics), an internal wave generation with the source function of Gaussian distribution and an energy absorbing layer. For the verification of new 3-D nonlinear wave driver, we numerically simulate the sloshing problem within a parabolic water basin triggered by a Gaussian hump and uniformly inclined water surface by Thacker (1981). It turns out that the qualitative behavior of sloshing caused by relaxing the external force which makes a free surface convex or uniformly inclined is successfully simulated even though phase error is visible and an inundation height shrinks as numerical simulation more proceeds. For the more severe test, we also simulate the nonlinear shoaling and refraction over uniform beach of wedge shape. It is shown that numerically simulated waves are less refracted than the linear counterpart by Hamiltonian ray theory due to nonlinearity, energy dissipation at the bottom and side walls, energy loss induced by breaking, and the hydraulic jump occurring when breaking waves encounter a down-rush by the preceding wave.