• Transactions of Materials Processing
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• v.4 no.2
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• pp.141-150
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• 1995

The purpose of the open die press forging is to maximize the internal deformation for better structural homogeneity and center-line consolidation in case of the ingot. A two and three dimensional viscoplastic finite element analysis is carried out for the plate, cylinder and square forging with the flat die in order to study the forging effects during the process. Effect of width, height reduction, and die staggering are studied through simulation of the process. Thus favorable working conditions are suggested for better and more disirable product quality.

• Transactions of Materials Processing
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• v.19 no.8
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• pp.480-485
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• 2010

In this work, the closing behavior of cylindrical-shaped voids was experimentally investigated according to various parameters such as reduction ratio in height, initial void size and billet rotation during hot open die forging process. The reduction ratio in height, number of path, and billet rotation were chosen as key process parameters which influence the void closing behavior including the change of void shape and size. On the other hand, values of die overlapping and die width ratio were set to be constant. Void closing behavior was estimated by microscopic observation. Based on the observations, it was confirmed that application of billet rotation is more efficient to eliminate the void with less reduction ratio in height. The experimental results obtained from this study could be helpful to establish the optimum path schedule of open die forging process.

• Transactions of Materials Processing
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• v.16 no.7
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• pp.502-508
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• 2007

Effect of the process parameters of the cogging process on the void crushing has been studied in order to identify the most effective factor. The process parameters considered in this study are die width ratio, reduction ratio and pre-cooling time before cogging process. Void crushing analysis with the selected process parameters was carried out using FE analysis. The results of FE analysis were evaluated by Taguchi method. It was found that the efficiency of void crushing increases with an increase in the values of all selected process parameters and the principal factor controlling the void crushing was identified as the reduction ratio.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.127-130
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• 2007

Effect of the forging process parameters on the void crushing is the cogging process has been studied in order to find the most effective factor. The Process parameters used for this study are die width ratio, reduction ratio and pre-cooling time before cogging process. Void crushing analysis about the selected process parameters was carried out using FE analysis. The results of FE analysis were evaluated by Taguchi method. It was found that the efficiency of void crushing increases with an increase in the values of all selected process parameters and the principal factor controlling the void crushing was identified as the reduction ratio.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.75-78
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• 2008

The predictive equation of void-closure was developed to evaluate void crush ratio with respect to the process variables in the cogging process of a large round bar. The comprehensive finite element analysis with the process variables such as reduction ratio and die width ratio was carried out. The predictive equation of void-closure for cogging process was established on the basis of the regression analysis with the extensive FE analysis results and verified by comparing the predicted results with FEA results with various forging passes.

• Korea-Australia Rheology Journal
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• v.11 no.3
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• pp.225-232
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• 1999

This study presents 1-dimensional simple model for sheet casting or rectangular fiber spinning process. In order to achieve this goal, we introduce the concept of force flux balance at the die exit, which assigns for the extensional flow outside the die the initial condition containing the information of shear flow history inside the die. With the Leonov constitutive equation that predicts non-vanishing second normal stress difference in shear flow, we are able to describe the anisotropic swelling behavior of the extrudate at least qualitatively. In other words, the negative value of the second normal stress difference causes thickness swelling much higher than width of extrudate. This result implies the importance of choosing the rheological model in the analysis of polymer processing operations, since the constitutive equation with the vanishing second normal stress difference is shown to exhibit the characteristic of isotropic swelling, that is, the thickness swell ratio always equal to the ratio in width direction.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.10a
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• pp.113-121
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• 1996

AI7075 alloy has been used for aircraft components since it has the advantage of high strength, high toughness, and high corrosion resistance. Many airframe components consist of various combinations of rib-web structure. In this study, various process paramenters such as die design, lubricant, ram speed, forging temperature have been investigated using the experiment and F.E.M. simulation to develop the precision forging technology for AI7075. When lubricant is applied to both material and die, shear friction factor is 0.1 which shows best effect of lubricant. It is specific corner radius of die that minimized forging load regarding process conditions, especially according to the ratio of the width of rib and web. In conclusion, optimum corner radius is 2~3mm when the width of rib and web is 3mm and 20mm respectively.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.11
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• pp.166-173
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• 1999

Al forged parts are many cases with rib-web section which is difficult to manufacture precisely. Therefore, process conditions must be optimized for precision forging of Al alloys. In this study, various process parameters such as die design, lubricant, ram speed, forging temperature have been investigated using the experiment, upper bound theory and F.E.M. simulation to develop the precision forging technology for rib-web shape component. When lubricant is applied to both material and die, shear friction factor is 0.1 which shows best effect of lubricant. It is specific corner radius of die that minimized forging load regarding process conditions, especially according to the ratio of the width of rib and web. In conclusion, optimum corner radius is 2~3mm when the width of rib and web is 3mm and 20mm respectively.

• Design & Manufacturing
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• v.2 no.3
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• pp.51-57
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• 2008

It is important factor to design the strip layout drawing according to product properties in press die design. Press dies are important processes in production such as a car component, house electronics, computer parts etc. In this paper, the strip layout of parts was designed for transfer dies. Results of this study can be modify the punch, trim position and notching shapes of strip layout. Utilization ratio was 70.3% by conducting piercing and notching for scrap design and materials were arranged with wide width of blank layout.

• Transactions of Materials Processing
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• v.13 no.2
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• pp.148-153
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• 2004

Finite element analysis of open die forging process to make rectangular billet has been performed in this study. Three dimensional rigid-plastic finite element method was used to analyze the effects of process variables, forging pass design and die configurations on the void closure phenomena to maximize the internal deformation for better structural homogeneity and center-line consolidation of the rectangular billet. The effect of anvil width ratio, anvil pitch, anvil shape and number of pass has been estimated by the degree of void closure ratio. Although it is difficult to optimize process parameters in the operational environments, favourable process conditions are suggested for better product quality.