• Journal of Drive and Control
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• v.19 no.4
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• pp.10-18
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• 2022

Air-drop hammer press and counterblow hammer press are widely used power-drop forging hammersemploying different forging blow mechanisms. It is important and necessary to analyze mechanical vibrations of these two different hammers in their forging processes in order to develop high performance forging hammers. In this study, these two forging hammers were mathematically modelled as mass-spring-damper systems. For these two different types of forging hammers, the forging efficiency and mechanical vibrations due to hammer forging blow were theoretically analyzed and compared. The force transmitted to the ground was also determined and compared. Especially, effects of mass ratio and restitution coefficient on forging efficiency were investigated.

• Korean Journal of Metals and Materials
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• v.50 no.8
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• pp.599-603
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• 2012

The microstructure of a hammer scale excavated from the Bogam-ri was examined in an effort to understand the iron technologies applied in the manufacturing of an iron forging process technology. The microstructures of oxide layer in the hammer scale were found to have crucial information about the ancient iron forging process treatment. The microstructure observed in the hammer scale can be distinguished by the forging process. First, the microstructure of the oxide layer in the hammer scale created by the forging process is Wstite (FeO) in the form of leaves. Latterly, the microstructure of the $W{\ddot{u}}stite$(FeO) in the hammer scale is observed to be in the form of a flat shape formed by a repeating forging process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.338-341
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• 2009

In this paper, three-dimensional finite element approach to determining the number of blows in hammer forging is presented. Energy efficiency which is a major factor affecting the number of blows in hammer forging is assumed to decrease linearly as die-material contact area increases. The approach is applied to predicting the number of blows in counterblow hammer forging of large crank shaft for medium sized ship engine.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.6
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• pp.1539-1544
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• 1995

Copper blow test to measure the forging capability of 35 ton counterblow hammer and upset of plasticine on the model hammer to investigate the change of the blow efficiency during the forging process have been performed together with finite element analyses of these experiments. The blow efficiency of the hammer has been found to be dependent on the friction and on the contact area between the die and the workpiece. The effects of the volume and the aspect ratio of the billet have not been found. Inferring from the experimental results and Schey's empirical formula on the forging load, we expect that the efficiency also varies with the flow stress of the workpiece material and with the shape complexity of the forging product.

• Korean Journal of Materials Research
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• v.13 no.6
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• pp.374-380
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• 2003

The effect of forging parameters, including different forging stock, strain rate and strain, on the mechanical properties of hot-forged Al 6061-T6 was investigated. The forging was conducted using either hydraulic press, crank press or hammer press, respectively, at a forging temperature of $400^{\circ}C$. When using an extruded bar as a forging stock, the tensile strength was lower for the specimens prepared by hammer forging than those by crank press forging. It was found that the coarsening of recrystallized grain was responsible for the decrease in tensile strength with hammer forging. Systematic studies on the effects of strain and strain rate on the tensile properties of hot-forged Al 6061-T6 products using extruded bar as a forging stock further suggested that the coarsening of recrystallized grains and$ Mg_2$Si precipitates complexed the observed trends in the tensile behavior. In case of hot forging with continuous cast bar as a forging stock, on the other hand, the mechanical properties of the specimen were largely improved with hammer press compared to those with crank press, which appeared to be due to the homogenization of microstructure.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.8
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• pp.43-52
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• 2022

The vibration characteristics of a hammer press are important parameters for machine design and production control. In this study, a counterblow hammer press was mathematically modelled as a mass-spring-damper system in order to analyze its vibration characteristics. The forging efficiency was theoretically derived as a function of the mass ratio, momentum ratio, and the coefficient of restitution And the effects of the mass ratio, momentum ratio and the restitution coefficient on the forging efficiency were also investigated for two particular cases of the unit mass ratio and unit momentum ratio. Additionally, the vibration responses of the counterblow hammer press due to the ram colliding impact were analyzed, and the force transmitted to the foundation through the mounting unit was determined.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.263-266
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• 2008

We apply a closed die forging technology to a large crankshaft of which forging weight amounts to 850kg. 40ton counter-blow hammer forging machine is used. The forging process is optimized to reduce the forming load using finite element simulation. AFDEX 3D is used for forging simulation. The experiment is compared with finite element prediction and a good agreement is observed. The successful development of a large crankshaft by the closed die forging technology will contribute to opening a new area of closed-die forging application and to enhancing competitiveness of national machinery industries especially including ship part and power generation industries.

• Transactions of Materials Processing
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• v.6 no.3
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• pp.250-256
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• 1997

Hammer forging was employed for Alloy 718 disk. The change in grain size during hot forging depends very much on dynamic recrystallization. The final grain size depends especially on the critical strain$($\varepsilon$_C)$/TEX> for dynamic recrystallization and Zener-Holloman parameter(Z). In this study, the critical strain$($\varepsilon$_C)$, the strain for 50 pct. recrystallization$($\varepsilon$_{0.5})$ and fraction of dynamic recrystallization(Xdyn) were measured by compression tests. FE simulation was also carried out ot predict the evolution of microstructure. The strain, strain rate and temperature distribution predicted by forging simulation can be effectively used to predict the distribution of grain sizes in the forged workpiece. The present model predictions showed an excellent agreement with the microstructural evolution of hammer-forged Alloy 718 disks.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.354-357
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• 2005

When Ti-6Al-4V is used in long steam turbine blades, the main issues are how to improve the fatigue strength as a problem of internal quality and how to forge the thinnest possible blades as problem of dimensional precision. To assure an excellent fatigue strength, it is important to make the two phase fine and equiaxial structure by providing enough plastic deformation in the two phase$(\alpha\;phase/\beta\;phase)$ temperature region. Accordingly, it needs to predict that forging temperature, preform design and forging velocity in forging process. To achieve this end, the two steps forging process was suggested to forge the thin and twisted blades with a precision hammer considering die forces and metal flow. Two steps forging process consists of the flattening forging process and finishing forging process. Process in forging of a 1016mm long steam turbine blade is designed by the finite element method. This study attempts to derive systematic design procedures for process design in the forging. Forging parameters was analyzed in two-dimensional plane-strain simulation and two steps forging process carried out in three-dimensional simulation. Consequently, optimal forging process parameters of long steam turbine blades in Ti-6Al-4V with a high dimensional precision are selected in the hammer die forging.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.186-189
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• 2001

In keeping with the needs of the times for energy and labor saving and simplifying production processes, interests has been growing in warm forging. Moreover, it is interested in increasing the material usage and production amounts. To improve the productivity and material usage, it is studied the process design of warm forging for socket. Until now, socket is manufactured by hot forging in hammer. The percentage of material usage is under $60\%$ in hammer forging. On the other han4 the percentage can be increased over $90\%$ in warm forging. To change the process from hot forging to warm forging, process designs must be performed. In this time, by using the FEM package, DEFORM-3D, we could get the shape of 1st process and minimum sealing pressure. They are very essential design data to decrease the trial and error. Practically, the overlap defect could be detected and eliminated with design modification of rib height and fillet radius. Moreover, forging load and minimum sealing pressure was defined by the 3D FEM analysis.