• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.05a
• /
• pp.88-91
• /
• 2003

The forging of Al 6061 has been studied by using finite element analysis and real forging experiment to find out the effect of strain rate and strain on the final forged product. It seems to be well known that the mechanical properties depend on the microstructures of forged products. The hot deformation of Al alleys including Al 6061 has been researched quite a long period on the various aspects. However, the forging of Al alloys seem to have few information, especially the recrystallization, recovery and grain growth. To elucidate the process variables to control those microstuctual aspects the specially designed model was used for finite element simulation and forging experiments, in which the variation of strain and strain rate could be obtained. The effect of strain md strain rate has been related with the microstructures of forging stocks.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.10b
• /
• pp.133-137
• /
• 2003

In this paper presented the net forging technology of planetary gear after much experiment and analysis, technology of two forging processes after billet being one -time heated, and cold net forging was adopted to ensure the gear forming quality. In the process of die producing, electrical rod NC cutting technology was used .the test and application has proved the net forging gear has reached higher quality and met the requirement of design. The net forging gear technology had been put into production.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1997.04a
• /
• pp.670-674
• /
• 1997

Semi-solid forging is a compound forging technology to deventional forging process. Among several steps of semi-solid forging process, the heating step of a billet prior to semi-solid forging step is necessarily required to obtain globular microstructure. For the forming operation to work properly, it is also important to heat the billet uniformly for the uniformity of solid-liquid distribution. To satisfy these requirements, induction heating has been generally used for a long time. This paper presents the method to find heating condition and the temperature distribution inside of a billet with a induction heating apparatus by comparing the computer simulation with experiment for aluminum alloys Al2024 and A356.

• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.8
• /
• pp.15-20
• /
• 1997

Semi-solid forging is a compound forging technology to develop conventional forging process. Among several steps of semi-solid forging process, the heating step of a billet prior to semi-solid forging step is necessarily required to obtain globular microstructure. For the forming operation to work properly, it is also important to heat the billet uniformly for the uniformity of solid-liquid distribution. To satisfy these requirements, induction heating has been generally used for a long time. This paper presents the method to find heating condition and the temperature distribution inside a billet with a induction heating apparatus by comparing the computer simulation with experiment for aluminium alloys A12024 and A356.

• IE interfaces
• /
• v.14 no.1
• /
• pp.1-8
• /
• 2001

This paper presented a web-based virtual system to simulate forging operation. The system utilized simulation techniques of Finite Element Method (FEM) to analyze the forging process and Virtual Reality Modeling Language (VRML) to visualize the simulation results in the web. The analysis using FEM could show mechanical information such as stresses and deformation profiles of a specimen during forging process and the analysis results were transferred into virtual space using VRML. Since the forging machine and specimen were modeled using Java and VRML, the forging machine and analysis results were browsed and integrated on the web that is interfaced to users through EAI to show the whole forging simulation. The developed system realized the working environment virtually so that education and experiment could be performed effectively even on the PC.

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

• Journal of the Korean Society for Precision Engineering
• /
• v.19 no.1
• /
• pp.180-185
• /
• 2002

Aluminum casting/forging process is used to produce an aluminum tie-rod end for the steering system of automobiles. Firstly, casting experiments were carried out to get a good preform for forging the tie-rod end. In the casting experiment, the effects of additives, Ti+B, Zr, Sr, and Mg, on the mechanical properties and the microstructure of a cast preform were investigated. And a finite element analysis was performed to determine an optimal configuration of the cast preform. Lastly, a forging experiment was carried out to make the final product of aluminum tie-rod end by using the above cast preform. In the casting experiments, when 0.2% Ti+B and 0.25% Zr were simultaneously added into molten Al-Si alloy, the highest values of tensile strength and elongation of the cast preform were obtained. When 0.04% Sr were added into the molten aluminum alloy, the finest silicon-structure was observed in the cast preform. The highest hardness was obtained when 0.2% Mg was added. In the forging experiment, It was confirmed that the optimal configuration of a cast preform predicted by FE analysis was very useful. The hardness of a cast/forged product using designed preform was superior to that of required specification.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.27 no.1
• /
• pp.152-157
• /
• 2003

Process design of hot forging, asymmetric to symmetric rib-web shape steel, which is used for the turnout of railway express has been investigated. Owing to the big difference in shape between the initial billet and the final forged product, it is impossible to hot forge the rail in a single step. Therefore, multi step forging as well as die design for each step are necessary for the production. The deformation behavior during hot forging has been analyzed by the numerical simulation through commercial FEA software, $DEFORM^{TM}$-2D. Modification of the design and repeated simulation have been carried out on the basis of the simulation result. For comparison with the simulation results. flow analysis experiment using plasticine has been also carried out. The results of the flow analysis experiment showed good agreement with those of the simulation. Therefore, the developed process design could be applied to the actual production.

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.18 no.7
• /
• pp.1685-1696
• /
• 1994

In this paper, a new forming process of the large-size forgings within the limit of forming loads is developed by introducing the incremental forging method and combined forming method. For the development of the forming process, various related processes are proposed and modelling experiments of plasticine and corresponding numerical simulation ate carried out. Thus, an optimal process considering the productivity and economical efficiency is recommended from the study of formability and forming loads, etc. The selected process is subjected to a modelling experiment of lead and 1/7 scale prototype experiment of the real material so as to verify the effectiveness of a selected process as well as to determine the design parameters. The developed process is then applied the forging product of dome shape. Dome-shaped forgings can be produced by the developed process within the limit loads and with the simple tools.

• Transactions of Materials Processing
• /
• v.17 no.8
• /
• pp.600-606
• /
• 2008

In closed-die hot forging, a billet is formed in dies such that the flow of metal from the die cavity is restricted. Some parts can be forged in a single set of dies, whilst others, due to shape complexity and material flow limitations, must be shaped in multi sets of dies. The purpose of a performing operation is to distribute the volume of the parts such that material flow in the finisher dies will be sound. This study focused on the design of preforms, flash thickness and land width by theoretical calculation and finite element analysis, to manufacture the super hot forging product, 70MC type piston crown used in marine engine. The optimal design of preforms by the finite element analysis and the design experiment achieves adequate metal distribution without any defects and guarantees the minimum forming load and fully filling of the cavity of the die for producing the large piston crown. The maximum loads obtained by finite element analysis are compared with the results of experiments. The loads of the analysis have good agreements with those of the experiment. Results obtained using DEFORM-2D enable the designer and manufacturer of super hot forging dies to be more efficient in this field.