• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.188-191
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• 2005

Lower arm for automobile has been made in steel traditionally. Nowadays steel is being substituted fur aluminum to reduce weight of automobile. Widely applied production method of aluminum component has been casting processes or cast/forging processes. But casting or cast/forging processes have limits of application to parts which is required high strength durability like automotive component. In this research, hot forging process has been adopted to produce aluminum lower arm to ensure required mechanical properties. To reduce production cost, 2 pieces with 1 blow process was developed. Optimization and verification of hot forging process for aluminum lower arm was performed by computer aided engineering using finite volume methods.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.905-909
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• 2001

The significance of casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from $420^{\circ}C$ to $450^{\circ}C$. The suitable strain rate was 1.5 $sec^{-1}$. The deformation amount of a preform in a forging process is key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of cast preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for the low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeds 0.7. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.71-75
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• 1999

An approximate similarity theory has been applied to predict the forming load of non-axisymmetric forging of aluminum alloys through model material tests. The approximate similarity theory is applicable when strain rate sensitivity geometrical size and die velocity of model materials are different from those of real materials. Actually the forming load of yoke which is an automobile part made of aluminum alloys(Al-6061) is predicted by using this approximate similarity theory. Firstly upset forging tests are have been carried out to determine the flow curves of three model materials and aluminum alloy(Al-6061) and a suitable model material is selected for model material test of Al-6061 And then and forging tests of aluminum yokes have been performed to verify the forming load predicted from the model material which has been selected from above upset forging tests, The forming loads of aluminum yoke forging predicted by this approximate similarity theory are in good agreement with the experimental results of Al-6061 and the results of finite element analysis using DEFORM-3D.

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.4
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• pp.69-74
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• 2001

Powder forging technology has been introduced to manufacture the parts for vehicles. This paper describes the process conditions for the powder forging of aluminium also piston for vehicles including the determination of composition of aluminum alloy by experiment, preform design by FEM simulation, coed compaction of aluminum alloy powder, sintering of preform, and the experiment of powder forging. The mechanical properties such as hardness, tensile strength, and elongation of the farmed piston were invested and compared with casted piston and forged piston. The tensile strength and hardness of the piston formed by powder forging technology were much more excellent than other pistons.

• Transactions of Materials Processing
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• v.32 no.1
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• pp.5-11
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• 2023

The aim of this study is to manufacture an aluminum pipe yoke of automotive steering system for lightweight. In a multistage cold forging process for aluminum pipe yoke, the surface defects frequently occur due to excessive deformation or friction during extrusion process for forming hollow pipe part. It is import to reduce the friction between the material and the forging die. This study investigated a multistage forging process with sliding die to reduce friction for aluminum pipe yoke. After evaluating by FE analysis, the forging experiment with the sliding die was carried out. As a result, it was possible to manufacture a sound aluminum pipe yoke.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1995.06a
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• pp.74-80
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• 1995

Forged aluminum lower arm has been developed to provide weight reduction of suspension parts. It was utilized FEM analysis in design of parts. Prototype parts were producted to two shape & different forging condition. Difference of forging condition was manufacturing process of stock, forging press, forging die, heat treatment condition. As a result, weight reduction of 44%, 38% was achived. Strength and fatigue endurance of forged aluminum lower arm was excellent.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.25 no.9
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• pp.1438-1443
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• 2001

The significance of the casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to reduce press capacity and material cost. Firstly, a hot compression test was performed with cast cylindrical billets in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from 420$\^{C}$ to 450$\^{C}$. The suitable strain rate was 1.5 sec(sup)-1. The deformation amount of a preform of a preform in a forging process is a key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of case preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeded 0.7. From the result of FE analysis, optimal configurations of the cast preform and the die were designed for a large flange. The filling and solidification analysis for a sound cast-preform was carried out with MAGMA soft. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.1
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• pp.204-208
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• 2000

An approximate similarity theory has been applied to predict the forming load of non-axisymmetric forging of aluminum alloys through model material tests. The approximate similarity theory is applicable when strain rate sensitivity, geometrical size, and die velocity of model materials are different from those of real materials. Actually, the forming load of yoke, which is an automobile part made of aluminum alloys(Al-6061), is predicted by using this approximate similarity theory. Firstly, upset forging tests are have been carried out to determine the flow curves of three model materials and aluminum alloy(Al-6061), and a suitable model material is selected for model material test of Al-6061. And then hot forging tests of aluminum yokes have been performed to verify the forming load predicted from the model material, which has been selected from above upset forging tests. The forming loads of aluminum yoke forging predicted by this approximate similarity theory are in good agreement with the experimental results of Al-6061 and the results of finite element analysis using DEFORM-3D.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.1
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• pp.49-55
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• 2022

Recently, the automobile industry has continued to demand lighter materials owing to international environmental regulations and increased convenience. To address this demand, aluminum parts have increased in popularity and are mainly developed and produced through hot forging and cold pressing. However, because this method has low yield and low production efficiency, a new manufacturing method is desirable. In this study, the water capacity efficiency of an aluminum inner tie rod socket was investigated using cold forging that provided a high yield and excellent production efficiency. Mechanical properties were derived through tensile testing of 6110A aluminum materials, and critical fracture factor and process analysis based on experimental data were carried out. The optimized process was applied as a prototype using cold multi-stage forging, and based on the derived results, the formability, productivity, and material efficiency of aluminum inner tie rod socket parts using this cold forging process was verified.

• Transactions of Materials Processing
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• v.27 no.5
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• pp.276-280
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• 2018

This paper has developed a forging process for conical shells for making aluminum cylindrical large shells. An incremental forging process was applied to reduce forging loads and die cost. The preform is designed based on the crosssectional area of the final forged shape. Inner diameter of the preform for mandrel forging is constant, and outer diameter is conical so that it matches the cross-sectional area of the product. However, simulation confirmed that the larger diameter is smaller than predicted and the length is larger than predicted because in the initial stage of forging, the large diameter portion first comes into contact with the anvil at the initial stage of forging and stretches in longitudinal direction. So, it has developed a rule to design the preform considering 3-D deformation instead of plane strain deformation at the beginning stage of mandrel forging. The developed mandrel forging process can be applied to more similar products and economic benefits may be obtained.