• Transactions of Materials Processing
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• v.24 no.6
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• pp.411-417
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• 2015

The piston engine is an essential component in automobiles. Since the piston is used in a high temperature and high pressure environment, the piston needs to be manufactured to achieve high strength and high durability. In addition, cost reduction is also an important consideration. In conventional forging, an additional heat treatment after hot forging is necessary to ensure proper mechanical properties for heavy-duty engine pistons. The newly developed manufacturing method lowers production costs by saving manufacturing time and reduces energy consumption. The current paper describes the hot forging of an engine piston made from 38MnSiVS5 micro-alloyed steel using controlled cooling. The finite element analysis was used to check for possible problems and suitable press capacity. Hot forging experiments were then conducted on a 2500tons crank press to evaluate feasibility of the proposed material and process. To check the mechanical properties after hot forging, the forged specimens were tensile tested, and the microstructures were examined in order to compare the results with the conventionally forged material. The skirt region of the as-forged 38MnSiVS5 piston showed better material properties compared to the conventional material. In addition, the total production time was reduced by about 80% as compared to conventional forging.

• 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.

• Transactions of Materials Processing
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• v.12 no.1
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• pp.18-25
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• 2003

This paper explains the process design for improving tool life in the conventional hot forging process. The thermal load and the thermal softening are happened by contact between the hotter billet and the cooler tools in hot forging process. Tool life decreases considerably due to the softening of the surface layer of a tool was caused by a high thermal load and long contact time between the tools and the billet. Also, tool life is to a large extent limited by wear, heat crack and plastic deformation in hot forging process. Above all, the main factors which affect die accuracy and tool life we wear and the plastic deformation of a tool. The newly developed techniques for predicting tool life are applied to estimate the production quantity for a spindle component and these techniques can be applied to improve the tool life in hot forging process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.993-996
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• 2005

This paper is concerned with transfer process on hot forging of bearing hub. Workers on hot forging have difficulty in working by high temperature and weight workpiece. And In conventional got forging of bearing hub, the material wasted to the flash accounts approximately 10% of the original workpiece. It is need manufacture automation and reduce the cost of forged products. Surface treatment of die and lubricant are investigated from experiment and FE-simulation for analysis of forming simulation. In order to hot forging process design considered flash thickness and blocker geometry and initial temperature of die and billet. This transfer process gave comparatively good results compared with actual products.

• Transactions of Materials Processing
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• v.3 no.3
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• pp.271-281
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• 1994

Titanium-6242 $({\alpha}+{\beta})$ alloy has been used for aircraft engine components such as disks and blades, because it has an excellent strength/weight ratio at high temperatures. When this material is forged to manufacture disks, process parameters should be carefully designed to control strain and temperature distributions within the process windows by which desirable mechanical properties can be produced. In the present investigation, it was intended to design the process parameters for a conventional hot forging of this material by using a rigid-thermoviscoplastic finite element analysis technique. It was assumed that the process was performed by a screw press which is capable of maintaining a constant ram speed during loading. From the analysis results, it was found out that the initial temperature of the workpiece and the die shape were important parameters to control the forging process. In result, these parameters were properly designed for hot forging of a disk with specific dimensions.

• 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.

• Transactions of Materials Processing
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• v.9 no.5
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• pp.533-538
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• 2000

This study has been carried out to develop a CRT die using hot forging. The conventional CRT die made by casting has defects such as void and inclusion. These defects of the cast die make micro-spots on the surface of the CRT which affect the quality of the final product. So, a hot forging process is developed to avoid these defects of CRT die by the model material test and the rigid-plastic FEM. Firstly, model material tests are carried out with plasticine billets in order to investigate the material flow pattern in the die cavity and to get the reasonable initial values for designing the preform in the FE simulation. And then a finite element analysis has been performed to Predict the preform and the forging load of a CRT die. We also suggest an integrated die-set which combines two die-sets into one die-set to save manufacturing time and cost in case of similar die-size.

• 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.5 no.2
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• pp.105-114
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• 1996

Recently, precision forging techniques are applied to manufacture spur gears. Compared to conventional machining, they produce parts of better mechanical properties and less residual stresses with a much higher production rate. In the present investigation a rigid-plastic three dimensional finite element method was applied to analyze hot forging and cold sizing of a spur gear by closed dies. The involute curve of a tooth profile was approximated by a circle close to the curve. Results of the analyses make it possible to predict local strengths of the gear die failure and an appropriate preform for cold sizing. It was found that the preform for cold sizing. It was found that the preform for the cold sizing is the most important because it determines whether the gears especially teeth can be successfully formed.

• Journal of Powder Materials
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• v.4 no.4
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• pp.258-267
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• 1997

The powder forging process is an attractive manufacturing route for bevel gears. It offers beneficial material utilization and the minimization of finishing operations over that of conventional hot forging. The paper describes the process conditions for the powder forging of bevel gear, for example, powder alloy design, preform design, deformation of sintered preform, forging processes. The characteristics of prototype gear are investigated with microstructure, the density distribution, surface roughness of tooth, bending strength test of tooth, etc. The results of the bending strength test may prove the mechanical properties of powder forged gear.