• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.21 no.6
• /
• pp.961-970
• /
• 1997

A numerical method is presented to predict and analyze the shape of a growing billet produced from the "spray forming process" which is a fairly new near-net shape manufacturing process. It is important to understand the mechanism of billet growing because one can obtain a billet with the desired final shape without secondary operations by accurate control of the billet shape, and it can also serve as a base for heat transfer and deformation analysis. The shape of a growing billet is determined by the flow rate of the alloy melt, the mode of nozzle scanning which is due to cam profile, the initial positio of the spray nozzle, scanning angle, and the withdrawal speed of the substrate. In the present study, a theoretical model is first established to predict the shape of the billet and next the effects of the most dominent processing conditions, such as withdrawal speed of the substrate and the cam profile, on the shape of the growing billet are studied. Process conditions are obtained to produce a billet with uniform diameter and flat top surface, and an ASP30 high speed steel billet is manufactured using the same process conditions established from the simulation.imulation.

• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.2
• /
• pp.129-135
• /
• 1997

Experimental studies have been carried out to obtain uniform cups by one operation of backward extrusion. A lot of factors on dimensional accuracy of backward extruded cups are billet material, billet shape, punch shape, punch velocity, geometry of tool, tool material, and lubrication etc. In manufacturing cup-shaped parts by backward extrusion, it is very important to design the initial billet shape or the preform. The objective of this paper is to find that the shape of the initial billet is related to dimensional accuracy and also to manufacture the more accurate product simultaneously reducing the loss of material as forming the shape of the initial billet by means of upsetting.

• Proceedings of the Korean Society of Propulsion Engineers Conference
• /
• 1996.05a
• /
• pp.209-216
• /
• 1996

The shape variation of billet was investigated by numerical method and spray forming work with variation of average substrate withdrawal velocity$\bar{V}$, withdrawal velocity change interval $\Delta$t and velocity deviation from average velocity $V_{dev}$. The shape and diameter with large$\bar{V}$, $\Delta$t, $V_{dev}$ vary seriously. When $\bar{V}$, $\Delta$t, $V_{dev}$ are smaller, the shape of billet is more simillar to that of the billet with constant withdrawal velocity. The average diameter of billet is determined by only $\bar{V}$, independent of $\Delta$t, $V_{dev}$. With $\bar{V}$, : 0.2 mm/sec $\Delta$t: 200 sec and $V_{dev}$. : 0.2mm/sec billet of constant diameter 230mm$\times$ height 1000mm were manufactured.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1997.03a
• /
• pp.148-152
• /
• 1997

A numerical method is presented to predict and analyze the shape and the temperature history of a growing billet produced form the "spray forming" which is a fairly new near net-shape manufacturing process. It is important to understand the mechanism of billet growing and the cooling history of the spray deposited body, because one can obtain a billet with the desired final shape without secondary operations by accurate control of the billet shape and, moreover, growing velocity together with the cooling rate define the microstructure of the final formed product. In the present study, a theoretical model is first established to predict the shape of the billet and next the transient axisymmetric heat conduction problem with growing domain is solved using the so called "front tracking finite element technique".ent technique".uot;.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2004.05a
• /
• pp.87-90
• /
• 2004

In this paper, net-shape forming of an automobile gear is investigated. Barrel, a component of automobile start motor, is adopted as a net-shape forming. In order to accomplish the goal of net-shape forming without cutting of tooth and cam after forming, forming ability is raised through billet treatment and die design. As a technique of billet treatment spheroidizing annealing of billet to get low hardness and molybdenum disulphide coating to get low contact friction between billet and die is carried out. One of critical points of die design, fillet radii variation of tooth of die is applied to get smooth surface of barrel after cold forging. As a measurement of tooth accuracy, distance between two pins and lead-tooth alignments are investigated. Cam profile accuracy is checked with a 3D measuring instrument. Results obtained from the tests revealed reasonable result with respect to design goal. By these results, the paper shows that reasonable results can be obtained by billet treatment and die design for net-shape forming.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1996.04a
• /
• pp.196-200
• /
• 1996

In general, cylinderical types of billet are use in the backward extrusion. It is difficult to obtain homogenious wall thickness by the backward extrusion using these. It is gradually increased that improving the accuracyand reducing the post machining of the final products. In manufacturing cup shaped parts by backward extrusion, it is very important to design optimal initial billet or preform. These can improve the accuracy of final products and remove the post machining processes. In this study, the influence of final parts geometry by the shape of initial billet as non machined types are discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1994.10a
• /
• pp.133-140
• /
• 1994

In this paper, we have proposed a new method to determine the initial billet for the forged products using a function approximation in neural networks. the architecture of neural network is a three-layer neural network and the back propagation algorithm is employed to train the network. By utilizing the ability of function approximation of neural network, an optimal billet is determined by applying nonlinear mathematical relationship between shape ratio in the initial billet and the final products. A volume of incomplete filling in the die is measured by the rigid-plastic finite element method. The neural network is trained with the initial billet shape ratio and that of the un-filled volume. After learning, the system is able to predict the filling region which are exactly the same or slightly different to results of finite element method. It is found that the prediction of the filling shape ratio region can be made successfully and the finite element method results are represented better by the neural network.

• Transactions of Materials Processing
• /
• v.14 no.2 s.74
• /
• pp.139-144
• /
• 2005

It was investigated that curved aluminum products with 'ㄷ' section or with 'h' section could be bended during extrusion by the extru-bending process. In order to make bending at the exit section of die, the flow of billet inside die cavity was controlled by the shape of billet. As results of the analysis of $DEFORM^{™}-3D$, it was known that the bending phenomenon at the die exit can be happened by the asymmetric section of billet. And it was known by the experiment with plasticine or aluminum material that an symmetric product with 'c' channel section and the product with flanged 'h' section could be bended because of asymmetric shape of billet.

• Transactions of Materials Processing
• /
• v.31 no.6
• /
• pp.344-350
• /
• 2022

Extruded Mg-Bi binary alloys are known to have an undesirable bimodal grain structure containing a large amount of coarse unrecrystallized grains. Accordingly, to improve the microstructural homogeneity of extruded Mg-Bi alloys, it is necessary to promote the dynamic recrystallization (DRX) behavior during hot extrusion. An effective way to promote DRX is an increase in nucleation sites for DRX through a pre-deformation process before extrusion, such as cold pre-forging and hot pre-compression. However, the application of these pre-deformation processes increases the cost of final extruded Mg products because of an increase in energy consumption and decrease in productivity. Therefore, a low-cost new continuous process with high productivity is required to improve the microstructural homogeneity and mechanical properties of extruded Mg alloys without a drastic increase in the entire process cost. This study proposes a new extrusion method using an extrusion billet with a truncated cone shape (i.e., tapered billet) instead of a conventional extrusion billet with a cylindrical shape. When the hot extrusion of a Mg-5Bi alloy is conducted using the tapered billet, the DRX behavior during extrusion is considerably promoted. The DRX fraction and average grain size of the extruded alloy significantly increase and decrease from 65% to 91% and from 225 ㎛ to 49 ㎛, respectively. Consequently, the extruded Mg-5Bi alloy fabricated using the tapered billet has a finer homogeneous grain structure and higher tensile elongation than the extruded counterpart fabricated using the cylindrical billet.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2004.05a
• /
• pp.31-34
• /
• 2004

A new extrusion process of the circular section product with helical fins could be developed by using rotating extrusion dies. The twisting of extruded product is caused by the twisted conical die surface connecting the die entrance section and the die exit section linearly. But, until now, because the process has used fixed extrusion dies, it needs high pressure in order to twist billet and form fin shape on the surface of billet. So, during extruding billet, in order not to twist billet, the extrusion dies is needed to rotate itself instead of twisting billet. And in order to rotate dies, the shape of inside contour of extrusion dies must have conical type with twisted Inclined die surface connecting the die entrance section and the die exit section linearly. The results of experiments show that, in spite of using twisted extrusion dies, twisting of the billet should not happen because of rotating dies in the opposite direction of twisting direction of billet during extruding billet, and, from the results, it shows that it can decrease the power of extrusion pressure and could prevent crack of teeth for fin forming.