• Journal of Advanced Marine Engineering and Technology
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• v.23 no.3
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• pp.379-388
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• 1999

Au upper bound elemental technique(UBET) program has been developed to analyze forging load die-cavity filling and optimum kinematically admissible velocity fields for flashless forging. The simulation for flashless forgings are applied plane-strain and axisymmetric closed-die forging with rib-web type cavity. The kinematically admissible velocity fields for inverse triangular and inverse trapezoidal elements are used to analyze flashless forging,. Experiments have been carried out with pure plasticine billets at room temperature. Theoretical predictions of the forging load in plane-strain and axisymmetric forging are in good agreement with experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.84-88
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• 2009

The nickel-based alloy Nimonic 80A possesses strength, and corrosion, creep and oxidation resistance at high temperature. The exhaust valves of low speed diesel engines are usually operated at temperature levels of 400-$600^{\circ}C$ and high pressure to enhance thermal efficiency and exposed to the corrosion atmosphere by the exhaust gas. Also, the exhaust valve is subjected to repeated thermal and mechanical loads. So, the nickel-based alloy Nimonic 80A was used for the large exhaust valve spindle. It is composed a 540mm diameter head and a 125mm diameter stem. It is developed large products by hot closed-die forging. Manufacturing process analysis of the large exhaust valve spindle was simulated by closed die forging with hydraulic press and cooled in air after forging. The preform was heated to $1080^{\circ}C$ Numerical calculation was performed by DEFORM-2D, a commercial finite element code. Heat transfer can be coupled with the deformation analysis in a non-isothermal deformation analysis. Mechanical properties of the large exhaust valve spindle were evaluated by the variety of tests, including microstructure observation, tensile, as well as hardness and fatigue tests, were conducted to evaluate the mechanical properties for head part of exhaust valve spindle.

• Transactions of Materials Processing
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• v.22 no.4
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• pp.183-188
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• 2013

Scroll compressors are widely used in air conditioning systems and in automobiles due to their low pressure loss, minimal vibrations, and light-weight. Open-die forging with back pressure is used to forge the rotating scroll, and it requires special care since the forging die can be severely damaged at the fixed end of the spiral cavity similar to a fracture of a cantilever beam. To overcome the inevitable weakness of the forging die due to such damage, an innovative design is necessary. In this study, structural analysis using the finite element method was conducted to determine the reason for the fracture of the forging die. A novel design to avoid stress concentrations and vertical deflection, causing serious damage to the die, is suggested.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.5
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• pp.1211-1219
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• 1995

An upper bound elemental technique (UBET) program has been developed to analyze forging load, die-cavity filling and effective strain distribution for flash and flashless forgings. The simulation for flash and flashless forgings are applied axisy mmetric and plane-strain closed-die forging with rib-web type cavity. Inverse triangular and inverse trapezoidal elements are used to analyze flashless forging. The analysis is described for merit of flashless precision forging. Experiments have been carried out with pure plasticine billets at room temperature. Theoretical predictions of the forging load and the flow pattern are in good agreement with experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.370-373
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• 2008

Small size gas turbine disk requires good mechanical strength and creep properties at high temperature. In this study, Waspaloy was used as a superalloy to satisfy these specifications. The control of microstructure was needed to satisfy material properties at high temperature. In order to do this, we studied forging conditions and material analysis. Therefore die and preform design conducted so that hot forged gas turbine disk could have a good microstructure. The die and preform shapes are designed with consideration of the predefined hydraulic press capacity and the microstructure of forging product. Also we carried out the hot compression test for Waspaloy in various test conditions. From these results, we obtained the forging conditions as material temperature, die velocity etc. To verify these forging conditions, we conducted FE simulations by means of the DEFORM 2D-HT. In this study, the hot closed die and preform designs were completed to offer high temperature material properties of a small size gas turbine.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.191-194
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• 2003

A crank throw, which is one of the part of crankshaft for a large diesel engine, is manufactured by both closed die forging and open die forging. For the improvement of productivity the open die forging method is usually adopted to manufacture it these days. In case of the open die forging for the crank throw, a preform shape is very important because it seriously affects final dimensions of the product. The purpose of this study is to investigate affective factors of the preform to obtain a good shape of final product through simulation and the results are compared to downsized lead experiments.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.9
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• pp.2234-2244
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• 1994

A process sequence of multi-operation cold forging for actual application in industry is designed with the rigid-plastic finite element method to form a constant velocity joint housing(CVJ housing). The material flow during the CVJ housing forming is axisymmetric until the final forging process for forming of ball grooves. This study treats the deformation as an axisymmetric case. The main objective of the process sequence design is to obtain preforms which satisfy the design criteria of near-net-shape product requiring less machining after forming. The process sequence design also investigates velocity distributions, effective strain distributions and forging loads, which are useful information in the real process design.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.338-341
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• 2004

The dimension of forged part is different with the die dimension by the various effects, such as, elastic deformation and thermal effect. And, the difference amounts are not same according to the forging conditions, for example, forging mode, flow stress, etc. Therefore, the use of FEA is effective to predict and update the required die dimension. However, the variables for FE simulation are also as many as variables in the experiment. The variables give very much effect to the accuracy of FE results. At first, the material model is very deeply affected to the estimated dimension of forged part. And the considering of loading and ejecting stages is also important to increase the dimensional accuracy. The experiment and FEA are performed to investigate the dimensional changes and accuracy in cold forging. Two types of upsetting are used to survey the effects of forging mode and stages.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.428-431
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• 2005

This paper describes the process design for hot forging of bearing hub. Forging processes of bearing hub are simulated using the rigid-plastic finite element method. In the process called closed die forging without flash, the design of blocker geometry is of critical importance. Forging processes designs are take advantage of computer aided Process planning and experts. But that is difficult to predict metal flow line. So the preform is designed by the expert, and modified through predict metal flow line by CAE. This paper is to approach preform design considered defect such as metal flow and unfitting etc. at the finisher process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.27-33
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• 2003

In closed-die forging process, blocker has been used to fill and distribute metal well in finisher die. Generally, the blocker shape was determined by an expert with many experiences. However, the manual blocker design process takes much time and efforts, so various automatic methods for the blocker design process have been suggested for the last three decades. The method with filtering in FFT (Fast Fourier Transform) for the blocker design provides general solution than other methods. But, due to the properties of FFT in time-frequency domain, this method has some drawbacks such as long calculation time, difficulty of local control and additional boundary process after filtering. In this study, DWT (Discrete Wavelet Transform), which is more flexible and is more wildly used than FFT, is applied to the blocker design. The method with filtering in DWT is very proper to design blocker in both 2-D and 3-D shapes. To verify the efficiency of this method, blockers of some models are designed and the results show that blocker design with DWT is effective fer the blocker designs