• Journal of the Korean Society of Industry Convergence
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• v.20 no.3
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• pp.245-256
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• 2017

In this study, we describe a new approach to real-time implementation of working path control for the forging and casting manufacturing process by vertical type articulated robot system. The proposed control scheme is simple in structure, fast in computation, and useful for real-time control of factory automation based on robot system. Moreover, this scheme does not require any accurate parameter information, nor values of the uncertain parameters and payload variations. Reliability of the proposed controller is proved by simulation and experimental results for robot manipulator consisting of arm with six degrees of freedom under the variation of payloads and tracking trajectories in Cartesian space and joint space. The vertical type articulated robot manipulator with six axes made in SMEC Co., Ltd. has been used for real-time implementation test to illustrate the enhanced working path control performance for unmanned automation of the forging and casting manufacturing process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.371-374
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• 2009

Die casting process has been used widely for complex automotive products such as the knuckle, arm and etc. Generally, a part fabricated by casting has limited strength due to manufacturing defects by origin such as the dendrite structure and segregation. As an attempt to offer a solution to these problems, forging has been used as an alternative process. However, the forging process provides limited formability for complex shape products. Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes. This paper presents the results of an A356 aluminum alloy sample, which were obtained by experiment and by simulation using DEFORM 3D. Samples of metal parts were subsequently fabricated by using hydraulic press machinery.

• Transactions of the Korean Society of Automotive Engineers
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• v.25 no.1
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• pp.111-115
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• 2017

This forged piston is proposed with a lighter weight and higher durability than a gravity casting piston for gasoline engines. However, a forged piston is very difficult to develop and mass-produce due to lack of basic technologies such as design, material and forging technique. First, we benchmarked existing forged pistons according to database design parameters. Second, we evaluated two solidification processes, continuous casting and spray forming, to produce heat-resistant alloy billets for forging. The spray forming process gives better mechanical properties at all temperatures, particularly at elevated temperatures except when poor formability is present. We used DEFORM simulation to determine the optimum process condition with billet from spray forming and successfully commercialized it with LF Sonata HEV.

• Journal of the Korean Society for Heat Treatment
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• v.15 no.3
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• pp.136-141
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• 2002

During warm and hot forging process of steels or aluminum alloys, dies are subject to early fracture, severe wear by thermo-mechanical stress. Especially, during the die-casting of aluminum alloys, the service life of dies is incredibly lowered. In this study we investigated the characteristics of TiBN films produced by PECVD. TiBN films showed very high hardness, excellent wear resistance, which could enhance the service life of die parts such as forging punch, die casting core pin successfully.

• Journal of the Korean Society of Industry Convergence
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• v.21 no.6
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• pp.369-378
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• 2018

This study proposes a new approach to real time implimemtation of shape recognition technology of die casting and forging parts based on robot vision for smart factory. The proposed shape recognition and inspection technology for forging and die casting parts is very useful for manufacturing process automatiom and smart factory including external form's automatic inspection of machanical or electronic panrs for the precision verification. The reliabiblity of proposed technology Ihas been illustrated through experiments.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.902-905
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• 2000

As the manufacturing processes of automotive engine piston, gravity die-casting, squeeze casting, hot forging and powder forging process are generally used for the various specifications. As the semi-solid forming(SSF) is compared with conventional casting such as gravity die-casting and squeeze casting for the characteristics of its process, the product without inner defects such as gas porosity and segregation can be obtained and its microstructure is globular grain. In SSF process, the materials are heated up to the temperature between the solvus and liquidus line at which the materials exists in the form of liquid-solid mixture. In this time, Discussion is given about reheating process of row material and results are presented regarding accurate temperature and process variables controlling for right solid fractions.

• International Journal of Precision Engineering and Manufacturing
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• v.4 no.2
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• pp.49-56
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• 2003

As semi-solid forging (SSF) is compared with conventional casting such as gravity die-casting and squeeze casting, the product without inner defects can be obtained from semi-solid forming and globular microstructure as well. Generally, SSF consists of reheating, forging, and ejecting processes. In the reheating process, the materials are heated up to the temperature between the solidus and liquidus line at which the materials exists in the form of liquid-solid mixture. The process variables such as reheating time, reheating temperature, reheating holding time, and induction heating power has large effect on the quality of the reheated billets. It is difficult to consider all the variables at the same time for predicting the quality. In this paper, Taguchi method, regression analysis and neural network were applied to analyze the relationship between processing conditions and solid fraction. A356 alloy was used for the present study, and the learning data were extracted from the reheating experiments. Results by neural network were in good agreement with those by experiment. Polynominal regression analysis was formulated using the test data from neural network. Optimum processing condition was calculated to minimize the grain size and solid fraction standard deviation or to maximize the specimen temperature average. Discussion is given about reheating process of row material and results are presented with regard to accurate process variables fur proper solid fraction, specimen temperature and grain size.

• Journal of Korea Foundry Society
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• v.22 no.1
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• pp.17-25
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• 2002

Recently, many studies have been carried out to process on the purpose of lightness in a transport parts because of the saving energy, the environmental problem. The cast-forging process can be expected to lower costs without decreasing the mechanical properties. So, the finest microstructure is needed to get for applying the cast-forging process with Al-Si alloy because the microstructure affects to the cast-forging process. For refinement treatment of eutectic Si and Al solid-solution phase, Sr and TiB were added in Al-Si alloys. The finest microstructure could be observed when 0.075 wt.%Sr and 0.1 wt.%TiB were added respectively. In this case, tensile strength and elongation much more increased than as casting. After high temperature deformation simulation test with grain refinement specimens was carried out, about 70N per unit $area(mm^2)$ of specimen was confirmed. After hot forging, tensile strength and elongation were increased. It was considered because casting defect was removed by compressive working.

• Journal of Power System Engineering
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• v.13 no.3
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• pp.47-52
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• 2009

The effect of forging start temperature, forging ratio on the microstructure and mechanical properties of B7B4 steel ware investigated. Microstructure of centrifugal casted B7B4 steel consisted of martensite and ferrite phase. The volume fraction of ferrite increased with increase of forging start temperature and decreased with increase of forging ratio. Tensile strength and hardness decreased with higher of forging start temperature, while impact value and elongation increased with higher of forging start temperature. With increase of forging ratio, tensile strength rapidly increased up to the forging ratio of 30%, and then slowly increased, but elongation was decreased. Hardness and impact value rapidly increased with increase of forging ratio.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.24 no.5
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• pp.489-495
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• 2015

Forging is a manufacturing process involving the shaping of metal using localized compressive forces and the process of deforming metal into a predetermined shape using certain tools and press according to the temperature. Forging provides stronger metal parts than that possible by casting or machining. Conventional clutch jaw parts have been developed through cold forging and precision machining; however, fabrication of integral clutch jaw parts for farm machinery has not been reported yet. These parts were developed by applying a complex forging technology combining cold and hot forging. The integrated forming technology proposed in this study will be useful for reducing the lead-time for manufacturing, improving the accuracy of products, and eliminating the welding process.