• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.399-402
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• 2006

The outer race of CV(constant velocity) joint is an important load-supporting automotive part, which transmits torque between the transmission gear box and driving wheel. The outer race is difficult to forge because its shape is very complicated and the required dimensional tolerances are very small. Traditional warm and cold forging methods have their own limitations to produce such a complex shaped part; warm forging requires complex system with relatively higher manufacturing cost, while cold forging is not applicable to materials with limited formability. Therefore, multistage forging may be advantageous to produce complex shaped parts. In order to build a multistage forging system, it is necessary to characterize mechanical properties in response to system design parameters such as temperature, forging speed and reduction. For the analysis of formability of multistage forging process, finite element method(FEM) has been used for the process analysis. As a model case, a constant velocity (CV) joint forging process is analyzed by FEM, since CV joint has a complex shape and also its required dimensional tolerances are very tight. The data acquired by FEM is compared with operational forging data obtained from an industrial production line. Based on this comparative analysis, multistage forging process for CV joints is proposed.

• Transactions of Materials Processing
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• v.21 no.8
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• pp.473-478
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• 2012

The yoke, a component of conventional motor-driven power steering system, often contains welding defects from its manufacturing process. To eliminate these defects, the precision cold forging process has been tried. In this study, the double-action complex forging has been used to manufacture a torsion joint yoke. The backward extrusion proved faster than the forward extrusion in forging of the product. The double-action complex forging process utilized an upper die composed of a punch, a punch guide, a disc spring and a coil spring. The forged material pushes up the punch guide, and then the disc spring and the coil spring balances the backward extrusion force. Consequently, the flow of material was essentially in the forward direction, resulting in a successful forging operation. The forging load of Al 6061-T6 was higher than that of the automotive structural hot rolled plate.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.4
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• pp.653-659
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• 2017

In this study, the complex forging process of an outer support ring was developed and the prototype was manufactured. The current process, hot forging and MCT machining, has a disadvantage of excessive material removal rates and longer machining hours. To overcome this disadvantage, a general shape is given through hot forging and the precision is achieved through cold forging. The complex forging process was developed with the minimal machining process. Forging analysis was carried out to design a forging process using the commercial program, Deform-3D. The hot and cold forging processes were set up based on the analyzed result. The mold and prototype were manufactured. Hardness, surface roughness, internal defect, the grain low line of the prototype were evaluated. The results showed no particular problems, and there were no problems in mass production. Using complex forging, the material was reduced by approximately 27 % compared to the process using hot forging and MCT machining. In addition, the production speed was improved 2.15 fold compared to that of hot forging and MCT machining. Through this study, a cost-effective process and mold design technology were established, which is expected to have positive effects on other related automotive parts production.

• Transactions of Materials Processing
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• v.16 no.3 s.93
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• pp.187-192
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• 2007

The finite volume method for forging simulation is examined to reveal its possibility as well as its problem in this paper. For this study, the finite volume method based MSC/SuperForge and the finite element method based AFDEX are employed. The simulated results of the homogeneous compression obtained by the two softwares are compared to indicate the problems of the finite volume method while several application examples are given to show the possibility of the finite volume method fur simulation of complex hot forging processes. It is shown that the finite volume method can not predict the exact solution of the homogeneous compression especially in terms of forming load and deformed shape but that it is helpful to simulate very complex forging processes which can hardly be simulated by the conventional finite element method.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1995.03a
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• pp.31-40
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• 1995

Powder metallurgy process has many advantages such as hight efficientyof material, mass productivity and complex shape production with good mechanical properties. Among the powder forming processes, incremental forging allows the consolidation to be achieved with amaller force then those required by conventional forging. In particular the proces known as rotary forging is an unique and prodominant process known as rotary forging is an unique and prodominant process in which the working constraints approximate to those in normal closed die forging. This study is concerned with the powder compaction by rotary forging process. An experimental rotary forging press with 500kN load capacity has been developed, which is equippe dwith the rotational conicla die inclined to the central axis of the press at arbitrary angle. It is found that the highly densified P/M parts can be obtained by rotary forging process and the material properties are superior to those of the conventrional sintered parts. The detailedcomparision of the mechanical properties by rotary forging process with those by conventional process are given.

• 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 Materials Processing
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• v.28 no.6
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• pp.321-327
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• 2019

In this study, a hot and cold forging process was investigated to produce a complex-shaped hub of dual clutch transmission with low material loss and high productivity. The process was designed by the commercial finite element (FE) analysis program, DEFORM-2D (hot forging) and 3D (cold forging). And, the material flow and ductile fracture characteristics were studied to check the surface crack initiation of the specimen. The simulation results indicated that the proposed process could manufacture the complex-shaped hub with no surface crack and high-efficiency compared to the conventional machining process. For verification the numerical results, the hub of the SCM440 was fabricated by the proposed process and the mechanical properties and microstructure evolution were studied. It was demonstrated that the suggested hot and cold forging process might be useful in producing the key components of the automobile industry as a high-efficiency and environmentally friendly process.

• Transactions of Materials Processing
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• v.7 no.6
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• pp.620-630
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• 1998

Conventional hot forging and thixoforging of Al 7075 alloy have been compared with respect to microstructures, formability and hardness. Two distinctive temperature-strain rate ranges for hot forging of Al 7075 alloy were observed from the results of simple compression tests with strain rates of 10-3∼101 sec-1 in the temperatures between $250^{\circ}C$ and $500^{\circ}C.$ In the dynamic recovery range (low temperature-high strain rate range) multi-stage forging was necessary to form a complex shape part due to the lack of formability. In the high temperature-low strain rate range, in which dynamic recrystallization takes place a complex shaped park could be formed by single-stage forging. About 50% cold working in the SIMA process was necessary to get a fine and homogeneous microstructures. Microstructural study suggest that thixoforged Al 7075 part has fine grains and homogeneous microstructures. Its hardness number is almost same to that of conventional hot forged part after aging treatment.

• 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.55-58
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• 2003

Many researches have been already done on the issues of high temperature deformation and the microstructural evolution. The information has been very useful for the plasticity industry, especially successful for the extrusion. However, the parts made with forging usually have a complex shape. It is difficult to control the distribution of the variables like strain, strain rate and temperature rise due to the working heat during a hot-forging process. Consequently, the microstructural variation could be occurred depending on the plastic deformation history that the forged part would get during a hot forging. In the present study, the microstructural characteristic of a hot-forged 6061 aluminum alloy has been discussed on the aspect of grain size evolution. A forging of 6061 aluminum alloy has been carried out for a complex shape with a dimensional variation. Also, finite element analysis has been done to understand how the deformation variables such as strain, strain rate give an influence on the microstructure of a hot forged aluminum product.