• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 추계학술대회 논문집
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• pp.197-198
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• 2008

The forging process produces complicated and designed components in a die at high productivity for mass production and minimizes the machining amount for favorable material utilization; the forging products used at highly stressed sections are well accepted at a wide range of industry such as automobile, aerospace, electric appliance and et cetera. Accordingly, recent R&D activities have been emphasized on improvement of forging die-life and near net shaping technology for cost effectiveness and better performance. Usually closing and consolidation of internal void defects in a ingot is a vital matter when utilized as large forged products. It is important to develop cogging process for improvement of internal soundness without a void defect and cost reduction by solid forging alone with limited press capacity. For experiments of cogging process, hydraulic press with a capacity of 800 ton was used together with a small manipulator which was made for rotation and overlapping of a billet. Size of a void was categorized into two types; ${\phi}$ 6.0 mm and ${\phi}$ 9.0 mm to investigate the change of closing and consolidation of void defects existed in the large ingot during the cogging process. In addition for forming experiment of piston grown air drop hammer with a capacity of 16 ton was used. The experiment with piston crown was carried out to show the formability and void closing status. In this paper systematic configuration for closing process of void defects were expressed based on this experiment results in the cogging process. Also forging defects through forming process for piston crown was improved using the experiment results and FE analysis. Consequently this paper deals with the effect of radial parameters in cogging process on a void closure far large forged products and formability of piston crown.

• 소성∙가공
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• 제14권5호
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• pp.432-438
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• 2005

Among the most of manufacturing process, plastic deformation method offers a significant advantage in productivity and enable mass production with controlled quality and low cost. From the point of view, micro forming is a well suited technology in manufacturing very small metallic parts, in particular for mass production, as they are required in many industrial products. Meanwhile, Al 5083 superplastic alloy with very small grains has a great advantage in achieving micro deformation under low stress due to its relatively low strength at a specific high temperature range. This paper describes the micro formability of Al 5083 superplastic alloy and its application to die forging of micro patterns. Micro formability tests of Al 5083 superplastic alloy were carried out with the specially designed micro forging system by using V-grooved micro dies and pyramidal dies made of (100) silicon. With these dies, micro forging was conducted by varying the applied load, material temperature and forging time The micro formability of Al 5083 superplastic alloy was evaluated by comparing $R_f$ value, where $R_f\;=\;A_f/A_v$ ($A_v$ : cross-sectional area of the flowed metal, $A_v$ : cross sectional area of V-groove). The micro formability of 3 dimensional Patterns was also evaluated using Pyramidal type micro dies.

• 소성∙가공
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• 제29권4호
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• pp.194-202
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• 2020

In this paper, experimental and numerical study on a combined sheet metal forming and plate forging of a seal part of a passenger car's hub bearing is conducted to develop the new process of which target is to remove machining process by plate forging and to achieve near-net shape manufacturing. The previous process of a sheet metal forming inevitably needed a machining process for making stepped sheet after conventional sheet metal forming in a progressive way. The stepped sheet is intended to be formed by plate forging in this study. Through the systematic way of developing the combined forming process using solid elements based-elastoplastic finite element method (FEM), several conceptual designs are made and an optimized process design in terms of geometric dimensioning and tolerance of straightness of the thin part is found, which is exposed to bending in metal forming of axisymmetric part. The predicted straightness measured by the slope angle of the tilted thin region is compared with the experimental straightness, showing that they are in a good agreement with each other. Through this study, a systematic approach to optimal process design, based on elastoplastic FEM with solid elements, is established, which will contribute to innovating the conventional small-scaled sheet metal forming processes which can be dealt with by solid elements.

• 한국산업융합학회 논문집
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• 제20권3호
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• pp.245-256
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• 2017

In this study, we describe a new approach to real-time implementation of working path control for the forging and casting manufacturing process by vertical type articulated robot system. The proposed control scheme is simple in structure, fast in computation, and useful for real-time control of factory automation based on robot system. Moreover, this scheme does not require any accurate parameter information, nor values of the uncertain parameters and payload variations. Reliability of the proposed controller is proved by simulation and experimental results for robot manipulator consisting of arm with six degrees of freedom under the variation of payloads and tracking trajectories in Cartesian space and joint space. The vertical type articulated robot manipulator with six axes made in SMEC Co., Ltd. has been used for real-time implementation test to illustrate the enhanced working path control performance for unmanned automation of the forging and casting manufacturing process.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2006년도 춘계학술대회 논문집
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• pp.377-380
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• 2006

Manufacturing process of Ti-6Al-4V alloy billet was investigated with FEM simulation and experimental analysis. Before the breakdown process of Ti-6Al-4V alloy ingot, FEM simulation for the breakdown processes of Ti-6Al-4V alloy ingot was used to calculate the forging load and state variables such as strain, strain rate and temperature. In order to breakdown the ingot structure and make an equiaxed structure billet, two different processes were employed for a VAR/VAR processed Ti-6Al-4V alloy ingot. Firstly, the ingot was cogged in single-phase $\beta$ field at the temperature of $1,100^{\circ}C$. In the process, the coarse and inhomogeneous structure developed by the double melting process was broken down. The second breakdown was performed by upsetting and cogging processes in $\alpha+\beta$ phase field to obtain the microstructure of fine equixed $\alpha$ structure in the matrix of transformed $\beta$. Finally, the mechanical properties of Ti-6Al-4V alloy billet made in this work were compared with those of other billet and ring product.

• 한국정밀공학회지
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• 제14권7호
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• pp.82-90
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• 1997

When a structure is made by the process of forging, it has the different mechanical properties from those it has before the process. This study is based on the crack closure phenomenon of the crack growth behavior of forged AI7050-T7452. The specimens were prepared in three kinds of forging ratio in order to find out the effects of crack closure on the forged material and compare the crack growth behavior with not-forged aluminum. COD method and strain gage method were used in measuring the crack closure stress and the results from those methods were compared each other. FEM analysis was applied to verify the effective stress intensity factor range by the superposition of the crack closure load to the crack tip. In the result of this study, the crack closure stress decreased with increasing the forging ratio due to the finer grain size and the brittle manner.

• 한국기계가공학회지
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• 제19권5호
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• pp.91-97
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• 2020

A split-die design for the cold forging of symmetric parts such as those having a hexagonal cross-section is presented in this paper. Parts with a hexagonal cross-section, such as bolt heads and nuts, should be forged with a die that has a hexagonal-shaped hole. A split type die is required to mitigate the buildup of stress concentrations located at the corners of the hexagonal hole. Generally, the insert of a hexagonal die is made by cutting each corner of a cylinder using a hexagonal hole and then combined with the die and shrink-fitted. However, split dies face problems when extruding material at the corners of the hexagonal split die. To address this problem, two types of split dies were evaluated: rounded hexagonal dies and angular hexagonal dies. The effects of the pre-stress ring on the dies were compared and analyzed and results show that using the angular split hexagonal die can extend the lifetime of forging dies.

• 한국자기학회지
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• 제5권5호
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• pp.416-420
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• 1995

An attempt has been made to investigate the mechanism of magnetic alignment in the magnets produced by upset forging the $Pr_{20}Fe_{74}B_{4}Cu_{2}$ cast bulk alloy. Upset forging of the cast alloy was carried out for 20 sec to an 80 % thickness reduction (strain rate : $4{$\times}10^{-2}s^{-1}$) in an open die configuration at varying temperatures in the range $600^{\circ}-900^{\circ}C$. It has been found that the upset forging process at temperatures above $800^{\circ}C$ can achieve a magnetic alignment to a great extent from copper-containing Pr-Fe- B-type cast ingot. The growth manner of the ferromagnetic $Pr_{2}Fe_{14}B$ matrix grain in Pr-Fe-B-type alloys was studied by examining the morphology change of the matrix grain in sintered body, and it was found that the matrix grains grew in anisotropic manner such that the grain grew more rapidly along the a- or b-axis than along the c-axis. This anisotropic grain growth led to the plate-like shape of the matrix grain. The magnetic alignment during the upset forging was attributed to grain boundary gliding of the plate-like grains, and the geometry of the grains in the cast ingot and the presence of a large amount of the praseodymium-rich grain boundary phase were thought to play a key role in the achievement of magnetic alignment.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.131-134
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• 2007

A semi-solid forming technology has a lot of advantages compared to the die casting, squeeze casting and hot/cold forging, so semi-solid forming has been studied actively. Semi-solid forming has two methods. One is thixoforming with reheating of prepared billet, the other is rheoforming with cooled melt until semi-solid state. Thixoforging technology can produce non-dendritic alloys for semi-solid forming complex shaped parts in metal alloys. In this study, the thixoforging was experimented with made rheology materials by the spiral stirrer equipment. Rheology materials for forging were made by A356 casting aluminum alloy and A6061 wrought aluminum alloy. After experiment, forged samples were measured microstructure and were heat treated for high mechanical properties.

• 소성∙가공
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• 제14권5호
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• pp.423-431
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• 2005

In this paper, a systematic attempt for estimating geometric dimensions of cold forgings is made by finite element method and a practical approach is presented. In the approach, the forging process is simulated by a rigid-plastic finite element method under the assumption that the die is rigid. With the information obtained from the forging simulation, die structural analysis and springback analysis of the material are carried out. In the springback analysis, both mechanical load and thermal load are considered. The mechanical load is applied by unloading the forming load elastically and the thermal load is by cooling the increased temperature due to the plastic work to the room temperature. All the results are added to predict the final dimensions of the cold forged product. The predicted dimensions are compared with the experiments. The comparison has revealed that predicted results are acceptable in the application sense.