• Transactions of Materials Processing
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• v.30 no.3
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• pp.142-148
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• 2021

In hot forging analysis, the interfacial heat transfer coefficient (IHTC) is a very important factor defining the heat flow between the die and the material. In particular, in the hot forging analysis of aluminum 6xxx series alloy, which are used in automobile parts, differences in load and microstructure occur due to changes in surface temperature according to the IHTC. This IHTC is not a constant value but changes depends on pressure. This study derived the IHTC under low load using aluminum 6082 alloy. An experiment was performed by fabricating a compression die, and a heat transfer analysis was performed based on the experimental data. The heat transfer analysis used DEFORM-2D, a commercial finite element analysis program. To derive the IHTC, heat transfer analysis was performed for the IHTC in the range of 10 to 50 kW/m²℃ at intervals of 10kW/m²℃. The heat transfer analysis results according to the IHTC and the actual experimental values were compared to derive the IHTC of the aluminum 6082 alloy under low load.

• Transactions of Materials Processing
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• v.29 no.4
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• pp.203-210
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• 2020

In this study, formability and springback behavior of 1.5 GPa grade ultra-high strength steel (UHSS) sheet were predicted through the finite element simulation, and structural stability of the forming dies was verified by the coupled forming-structural analysis. Uniaxial tension and uniaxial tension-compression tests were performed to obtain experimental data for modeling the springback properties of the sheet material. The springback values predicted by simulation were compared with those from actual measurements. The results calculated from the kinematic hardening model were found to be much more accurate than those from the isotropic hardening model. Deformation of the forming die and springback of the product were calculated by the coupled forming-structural analysis. The higher the strength of the die material, the smaller the surface displacement of the die and the springback of the product. The internal stresses of the dies made of three materials, FC300, FCD550 and STD11 were compared with the yield stress of each material. The results provided a basis for determining the most suitable material for each part of the die set. As a result, simulation techniques have been established for predicting formability and springback in the UHSS sheet forming process.

• Design & Manufacturing
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• v.14 no.4
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• pp.11-16
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• 2020

In this study, forming of carbon composite parts was performed using an injection/compression molding process. An impregnation of matrix is determined by ability of wet and flow rate between the matrix and reinforcement. The flow rate of matrix passing through the reinforcements is a function of permeability of reinforcement, a viscosity of matrix and pressure gradient on molding, and the viscosity of the matrix depends on the mold temperature, molding pressure and shear strain of matrix. Therefore, compression molding experiment was conducted using a heating mold in order to confirm the possibility of matrix impregnation. The impregnation of the matrix through the porosities between the woven yarns was confirmed by the cross-sectional SEM image of compression molded parts. An injection molding process was also performed at a short cycle time, high molding pressure and low mold temperature than those of compression experiment conditions. Deterioration of impregnation on the surface of molded parts were caused by these injection conditions and it could be the reason of decreasing the maximum tensile strength. In order to improve impregnation of matrix on the surface, injection/compression molding and insert-over molding were applied. As a result of applying injection/compression molding and insert-over molding, it was shown that the improvement of impregnation on the surface and the maximum tensile strength was increased about 2.8 times than the virgin matrix.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.3
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• pp.796-805
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• 1996

A fabrication process using Semi-Solid Material(SSM) for casting alloy has been studied to demonstrate the possibility for mass production with controlled solid fraction. The SSM was fabricated under the various solid fractions and preheating temperatures of mold. The behaviour of a semi-solid global microstructure has been investigated under the various heating and die temperatures for solid fraction. The effect of reheating time on the globularization of SSM microstructure has been investigated in detail. And the behavior of SSM which has the solid fraction 0.5 was observed under compression. The stress strain relationship was also obtained for the compression test of semi-solid materials. The rheological behaviour of semi-solid with globule microstructure was investigated as a function of the compression velocity under isothermal holing conditions.

• Design & Manufacturing
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• v.14 no.1
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• pp.22-29
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• 2020

The analysis was carried out using the press molding analysis program by applying six parameters such as material type change, material thickness, friction coefficient, r_p, r_d and blank holder pressure. As a result of CAE analysis of the soft material DC04 and the relatively hard material HX300LAD, the thickness of the punch R part of the soft material was significantly reduced. The flange portion is greatly increased in thickness in the hard material by the compression action. As a result of considering the deformation amount of 0.6mm, 1.0mm, 1.5mm according to the material thickness, the influence of the thickness is considered to be very small. In case of the material thickness of 0.6mm, the rate of change increases due to the deep drawing depth relative to the material thickness. The sizes of the punches R and die R have the greatest influence on the change in thickness of the material in drawing molding, the smaller the punch R, the thinner the edges of the product, The larger the R of the die, the greater the material thickness of the flange portion. As the coefficient of friction and the blank holder pressure increase, the frictional force of the flange portion increases, which increases the radial force in the drawing process and increases the thickness change of the flange portion.

• Journal of the Korean Society for Heat Treatment
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• v.7 no.1
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• pp.61-71
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• 1994

This study is to investigate the stress distributions, crystal orientations and magnetic properties during die-upsetting according to working temperature of Nd-Fe-B-Cu alloys. The stress distributions in the specimens during compressing process were calculated by a finite element method program(SPID). The calculated stresses were effective stress (${\sigma}_{eff}$), compression stress(${\sigma}_z$), radial direction stress(${\sigma}_r$) rotational direction stress(${\sigma}_e$) and shear stress(${\tau}_{rz}$). The stress distributions of ${\sigma}_z$, obtained by a computer simulation showed that the stress components causing the magnetic alignment during die-upsetting of the cast magnets were very high at the center-part of a specimen, and decreased toward the periphery-part of a specimen. In view of the above results the magnetic properties should be better at the center-part of a specimen than any other parts. But the measured magnetic properties were better at the mid-part. These results should be due to the fact that the specimens were casted. Normally the magnetic properties are affected by the casting process as well as by the stress levels. ${\sigma}_r$, ${\sigma}_e$ are thought to affect the liquid phase flowing and domain patterns, respectively. The influence of ${\tau}_{rz}$ was trivial, ${\sigma}_{eff}$ distributed similar throughout the specimen. The Nd-rich phase appeared at the peripheral of the specimen where the stress level of ${\sigma}_r$, ${\sigma}_z$, was low or the stress level of ${\sigma}_e$ was high. The Nd-rich phase was squeezed out during die-upsetting. This phase had an effect on the crystal orientation and grain growth. The stress distributions of alloy were irregular at the parts of the specimen where the die contacted with specimen.

• Transactions of Materials Processing
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• v.16 no.4 s.94
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• pp.293-298
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• 2007

Recently, there is a need to produce a large forged part for the flight, shipping, some energies, and military industries, etc. Therefore, an open die forging technique of cast ingots is required to obtain higher quality of large size forged parts. Cogging process is one of the primary stages in many open die forging processes. In the cogging process prior to some open die forging processes, internal cavities have to be eliminated for defect-free. The present work is concerned with the elimination of the internal cavities in large ingots so as to obtain sound products. In this study, hot compression tests were carried out to obtain the flow stress of cast microstructure at different temperature and strain rates. The FEM analysis is performed to investigate the overlap defect of cast ingots during cogging stage. The measured flow stress data were used to simulate the cogging process of cast ingot using the practical material properties. Also the analysis of cavity closure is performed by using the $DEFORM^{TM}-3D$. The calculated results of cavity closure behavior are compared with the measured results before and after cogging, which are scanned by the X-ray scanner. From this result, the criteria for deformation amounts effect on the cavity closure can be investigated by the comparison between practical experiment and numerical analysis.

• Transactions of Materials Processing
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• v.23 no.2
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• pp.116-121
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• 2014

Low pressure die casting and flow forming have been successfully used to produce sound road wheels from magnesium alloy AM80. In the current study, high speed compression testing was initially conducted to simulate the flow forming of a Mg wheel. Subsequently the flow forming was simulated with "Forge$^{TM}$", an FEM software package. On the basis of flow forming simulations, the flow forming of the Mg wheel was performed under different conditions. For the flow forming experiments, the preform castings were made by low pressure die casting from AM80, a commercial magnesium alloy. In flow forming of the magnesium preform wheel, the flow forming of the Mg wheel was successfully accomplished when the feed rate was less than half that for the forming of an aluminum road wheel. The reduction in feed rate was 52%. Finally, a comparison with the flow forming simulations was made.

• Transactions of Materials Processing
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• v.21 no.3
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• pp.207-214
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• 2012

High temperature deformation behavior of a $Ni_{30}Fe_{53}Co_{17}$ alloy, with its extraordinary low coefficient of thermal expansion less than $10{\times}10^{-6}K^{-1}$ at temperatures ranging from room temperature to 673K, was investigated by conducting a series of compression tests. From an empirical processing map, the appropriate working temperature-strain rate combination for optimum forming was deduced to be in the ~1373K, $10^{-2}s^{-1}$ region. This region has a relatively high power dissipation efficiency, greater than 0.36. Furthermore, open die forging of a 100mm diameter billets was performed to confirm the variation of thermo-physical properties in relation to microstructure. The coefficient of thermal expansion was found to increase considerably with increasing the open die forging temperature and decreasing the cooling rate, which in turn provides a drastic increase in the average grain size.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.190-194
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• 2007

The forging process design and microstructure evolution for gas turbine disk of a Waspaloy is investigated in this study. Parameters related to deformation are die and preform geometry, and forging temperature of die and workpiece. Die and preform design are considered to reduce the forging load, and to avoid the forging defects. Blocker and finisher dies for multistage forging are designed and the initial billet geometry is determined. The control of hot forging parameters such as strain, strain rate and temperature also is important because the microstructure change in hot working affects the mechanical properties. The dynamic recrystallization evolution has been studied in the temperature range 900-$1200^{\circ}C$ and strain rate range 0.01-1.0s-1 using hot compression tests. Modeling equations are required represent the flow curve, recrystallized grain size, recrystallized volume fraction by various tests. In this study, we used to thermo-viscoplastic finite element modeling equation of DEFORM-2D to predict the microstructure change evolution during thermo-mechanical processing. The microstructure is updated during the entire thermal and deformation processes in forging.