• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.50-52
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• 2007

Large size forged parts usually were made by hot open die forging because of the die cost, high applied load and small manufacturing quantities. Cast ingots were used in open die forging and the ingots almost included the cavities in its inside. Therefore, one of the aims for forging processes is to close and remove the cavities. However, its criteria were well not defined since the studies have many difficulties to investigate the cavity behaviors because of its large size. In this study, the cavity closure behavior was investigated by experimental and FE analysis. The FEM analysis is performed to investigate the overlap defect of cast ingots during free forging stage. The measured flow stress data were used to simulate the forging 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 forging, 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.6 no.5
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• pp.395-399
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• 1997

There exists a certain functional relation between Vickers hardness and flow stress in the strain-hardened material. Using this relation, the Vickers hardness values in the strain-hardened material can be converted into the flow stress values in good approximation. Therefore, the information about the flow stress distribution in the material can be easily acquired through a forming experiment. That makes it possible to simulate the process state for a critical moment of cold forging under the given boundary conditions very quickly without calculating the foregoing history of the actual deformation from the beginning.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.210-216
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• 1994

The velocity fields can be composed by nodal points using shape function. Forging load and deformed profile are obtained by minimizing total energy consumption rate which is function of unknown velocities at each nodal points. The velocity and stremiline distribution can also be investigated at the deformation profile. The effectiveness of proposed method in this paper is demonstrated by comparing with those of FEM and experiment, that is the results of upset forging problem. Obtained results are compared with FEM and experiment and fairly good agreement is found between them.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.905-909
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• 2001

The significance of casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from $420^{\circ}C$ to $450^{\circ}C$. The suitable strain rate was 1.5 $sec^{-1}$. The deformation amount of a preform in a forging process is key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of cast preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for the low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeds 0.7. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.371-374
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• 2009

Die casting process has been used widely for complex automotive products such as the knuckle, arm and etc. Generally, a part fabricated by casting has limited strength due to manufacturing defects by origin such as the dendrite structure and segregation. As an attempt to offer a solution to these problems, forging has been used as an alternative process. However, the forging process provides limited formability for complex shape products. Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes. This paper presents the results of an A356 aluminum alloy sample, which were obtained by experiment and by simulation using DEFORM 3D. Samples of metal parts were subsequently fabricated by using hydraulic press machinery.

• Transactions of Materials Processing
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• v.8 no.4
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• pp.384-392
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• 1999

In metal forming, there are problems with recurrent geometric characteristics without explicitly prescibed boundary conditions. In such problems, so-called recurrent boundary conditions must be introduced. In this paper, as a practical application of the proposed method, the precision cold forging of a helical gear has been simulated by a three-dimensional rigid-plastic finite element method and compared with the experiment. The application of recurrent boundary conditions to helical gear forging analysis is proved to be effective and valid. the elastic stress analysis of the die for helical gear forging has been calculated by using the nodal force at the final stage obtained from the rigid-plastic finite element analysis. In order to obtain more precise gear products, the elastic analysis of the die after release of punch and the elastic spring-back analysis of product after ejection have been performed, and the final dimension of the computational product has been in good agreement with that of the experimental product.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.107-110
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• 1999

The purpose of this research is for the development of a new type forging equipment H.C.G(Hyundai Continuous Grain-flow) by using two virtual build-up tools rigid viscoplastic FEM and downsized plasticine experiment. This forging equipment consists of consecutive horizontal and vertical pressure while the traditional forging method consists of only vertical pressure. Using this method high quality crankshafts can be forged as it can maintain a continuous grain flow. The factors considered in the development of equipment are die geometry for flawless deformed shape die reaction forces stress/strain distributions and continuous material flow. We carried out several numerical simulations and downsized plasticine experiments for the proper design of the forging equipment. The validity of those simulation results is confirmed by checking with the actual test results. Based on these simulation results the proper design of the H.C.G for ging equipment is enabled.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.223-228
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• 1994

A new velocity formulation technique, which contains the advantage of UBET and the shape function of FEM, is proposed. In the proposed technique, a shape function is used to improve the unreasonableness of elemental partition and to solve the difficulty of velocity-field determination. In order to verify the effectiveness of this rechnique, T-shaped forging processes are simulated. The results are compared with these obtained by experimental measurements in T-shaped forging. In T-shaped forging, good agreements between theory and experiment are also confined.

• Transactions of Materials Processing
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• v.8 no.3
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• pp.237-244
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• 1999

The purpose of this research is for the development of a new type forging equipment. H.C.G.(Hyundai Continuous Grain-Flow), by using two virtual build-up tools, rigid viscoplastic FEM and downsized plasticine experiment. This forging method consists of only vertical pressuree. Therefore, high quality crankshafts can be forged with this method as it can maintain a continuous grain flow. The factors considered in the development of equipment are die geometry for flawless deformed shape, die reaction forces, stress/strain distributions and continuous material flow. We carried out several numerical simulations and downsized plasticine experiments for the proper design of the forging equipment. The validity of those simulation results is confirmed by checking with the actual test results. Based on these simulation results, the proper design of the H.C.G. forging equipment is enabled.

• Transactions of Materials Processing
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• v.10 no.1
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• pp.67-74
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• 2001

The cold forging process to produce a long-neck flange is investigated by using model material test. The two stage process with optimum design condition is examined using plasticine, which is suitable to model steel at room temperature. The similarity theory is employed to estimate the forging load of each sequence by strict application of similarity condition between steel(AISI 1015) and plasticine material The model test results are compared with the simulation results and shows good agreement. The proper forging process with least forming energy can be resulted in $25^{\circ}$ of extrusion semi-die angle.