• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.1101-1104
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• 2004

A brake spider in an irregular shape, which is used as a part in the braking system of a vehicle like a big truck and a trailer, is subjected to a large torque and hence requires both strength and endurance over the brake heat. Manufacture of this product in practice is generally composed of hot forging processes and machining. At the present study, two or more processes were considered for the hot forging. With an initial circular billet, blocker and finisher processes were analyzed using the rigid-plastic finite element method and also in addition to the preforming process. Proper forging processes to manufacture an irregular product without forging defects, which are preforming, blocker and finisher, were discussed and commented upon.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.4
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• pp.83-90
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• 2018

In this research, we developed a process design hot-forging technology that precisely forms an inner race. The inner race transmits power to a one-way clutch of an automatic transmission and minimizes the CNC machining allowance. For a multi-stage hollow shape (inner race), we proposed several shapes of blocker and finisher for the precision hot-forging process and analyzed the forging process using DEFORM. The hot-forging process was optimized for several parameters, such as metal flow pattern, forging defect, and forming load. Blockers and finisher dies in the hot-forging process were designed to select optimal shapes from finite element analysis, and experiments were conducted to optimize the hot-forging process.

• Design & Manufacturing
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• v.6 no.2
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• pp.24-30
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• 2012

In this study, the hot forging technology for precision forming of spline teeth of the inner race in the auto-transmission was developed in order to minimize its finishing allowance. Several blocker and finisher shapes for the precision hot forging process of the inner race were proposed and the forging processes were analyzed using the three-dimensional finite element method. The optimum hot forging process was obtained considering some parameters such as metal flow patterns, forging defects and forming load. Blocker and finisher dies for the hot forging process were designed by selecting the most suitable shapes obtained from the finite element analysis. Experimental works were also performed in order to verify the optimum design of hot forging process.

• 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.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.3
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• pp.56-62
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• 2014

During the hot forging process, the most common cause of tool failure is wear. Tool wear results in the gradual loss of part tolerances, after which eventually the tool must be replaced or repaired. In order to maximize the lifetimes of forging tools, it is important to investigate the wear mechanisms of these tools. In this study, the hot forging of the outer race of an automotive constant-velocity joint was analyzed by a finite element method to investigate the wear distribution, especially the amount and location of the maximum expected wear damage, using Archard's wear model, which was modified considering the forging temperature. Forging analyses were carried out after modifying blocker forging tools based on established versions. The modified blocker tools resulted in an increase in the tool life up to 31% with a finisher punch.

• International Journal of Fuzzy Logic and Intelligent Systems
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• v.8 no.1
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• pp.24-30
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• 2008

A simulation of hot strip finishing mill automatic gauge control (AGC) system is built, which is divided into four modules such as rolling mill system, AGC module, looper system and strip model. The rolling mill system is built by mechanism modeling, the looper system and strip model are built by function modeling, and the AGC model is tried to use intelligent control of a multi-function AGC system. The target is attempted to use this simulation object to minimize finisher exit strip thickness deviation resulting from strip entry thickness disturbance and rolling force deviation. Simulation results show that the result of this AGC/LPC synthetical system module simulation is quite close to the actual result. The simulation system can also analyze most kinds of disturbance which affect the rolling process. It is proved that the system can represent practical situation of hot strip finishing mill process control, and be used as a basic platform of research and development for researcher and engineer.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.4
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• pp.118-124
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• 1998

The die wear is one of the main factors affecting die accuracy and tool lifetime. It is desired to reduce die wear by developing simulation method to predict wear based on process variables, and then optimizing the process. Therefore, this paper describes methodology of preform design for minimizing wear of finisher die in multi-stage cold forging processes. The finite element method is combined with the routine of wear prediction. The cold forging process is analyzed using developed simulation method. In order to obtain preform to minimize die wear, the Flexible Polyhedron Search(FPS) algorithm is used. The optimal preform shape is found from iterative deformation analysis and wear calculation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.10a
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• pp.164-167
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• 1997

The die wear is one of the main factors affecting die accuracy and tool lifetime. It is desired to reduce die wear by developing simulation method to predict wear based on process parameters, and then optimize the process. Therefore, this paper describes disign methodology of preform for minimizing wear of finisher die in multi-stage cold forging processes. The finite element method is combined with the routine of wear prediction and the cold forging processes. The finite element method is combined with the routine of wear prediction and the cold forging process is analyzed. In order to obtain preform to minimize die wear, the FPS algorithm is applied and the optimal preform shape is found from iterative deformation analysis and wear calculation.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.12
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• pp.2970-2981
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• 1993

In hot closed-die forging the load increases rapidly near the final stage. Preforming operation is important to both the sound final forging and die-service life. In this study, the material flows during preforming and final forging are investigated. The physical modeling with Plasticine as a model material showed clear flow patterns. The forging process were numerically simulated by the finite element method with the isothermal and the non-isothermal models. The flow patten of the isothermal simulation showed good agreements with the experiments. Temperature changes and pressure distributions on the die surfaces during one cycle of the forging process were obtained from the non-isothermal simulation. High pressure and temperature were developed at certain areas of the die surfaces. It was concluded that those areas usually coincide with each other and should be distributed by the preforming operations to enhance the die life.

• 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