• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09b
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• pp.1000-1001
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• 2006

Two atomized alloy powders were pre-compacted by cold and subsequently hot forged at temperatures ranging from 653K to 845K. The addition of Cu and Mg causes a decrease in the eutectic reaction temperature of Al-10Si-5Fe-1Zr alloy from 841K to 786K and results in a decrease of flow stress at the given forging temperature. TEM observation revealed that in addition to Al-Fe based intermetallics, $Al_2Cu$ and $Al_2CuMg$ intermetallics appeared. The volume fraction of intermetallic dispersoids increased by the addition of Cu and Mg. Compressive strength of the present alloys was closely related to the volume fraction of intermetallic dispersoids.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09a
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• pp.559-560
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• 2006

Powder forging is used for heavy-loaded parts (rings of rolling-contact bearings, gears etc.) production. Rolling contact fatigue is material property values of which characterize possibility of practical utilization of such parts. Rolling contact fatigue of some steels obtained out of prealloyed powders Astaloy CrM, Atomet 4601, Atomet 4901 and powder blends iron-carbon-nickel by hot forging is studied in the present paper. Effect of various kinds of heat and thermomechanical treatment on rolling contact fatigue is determined. Thermomechanical treatment provides optimal values of rolling contact fatigue. In this case steel structure contains up to 40% of retained metastable austenite which is transformed to martensite on trials. Thus typically crack is generated on residual pores and non-metallic inclusions instead of martensite zones in wrought steels.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.79-83
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• 2008

We carry out three-dimensional simulation of pore closing processes during upsetting in open die forging. Several pores on a plane section of a cylindrical material are traced at the same time and the results of hydrostatic pressure and effective strain are discussed to reveal the parameters affecting pore closing phenomena. Five different sizes of pores are also investigated by simulation to reveal the pore size effect in pore closing during upsetting. AFDEX 3D is employed for this study.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.47-50
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• 2003

Grain size of the $\alpha$ phase is computed during isothermal forging of the TC6 aerofoil blade, by combining FE with the Yada's model of grain size. The present results illustrate the grain size and distribution of the $\alpha$ phase during isothermal forging of the TC6 aerofoil blade' in detail. The computed results show that height reduction, deformation temperature, hammer velocity and friction have significant effect on distribution of the equivalent strain, and that height reduction, deformation temperature and hammer velocity have more significant effect on grain size of the $\alpha$ phase than friction between billet and die.

• Transactions of Materials Processing
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• v.16 no.4 s.94
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• pp.293-298
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• 2007

Recently, there is a need to produce a large forged part for the flight, shipping, some energies, and military industries, etc. Therefore, an open die forging technique of cast ingots is required to obtain higher quality of large size forged parts. Cogging process is one of the primary stages in many open die forging processes. In the cogging process prior to some open die forging processes, internal cavities have to be eliminated for defect-free. The present work is concerned with the elimination of the internal cavities in large ingots so as to obtain sound products. In this study, hot compression tests were carried out to obtain the flow stress of cast microstructure at different temperature and strain rates. The FEM analysis is performed to investigate the overlap defect of cast ingots during cogging stage. The measured flow stress data were used to simulate the cogging 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 cogging, 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.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.8 no.1
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• pp.24-30
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• 2009

In this paper, the effect of heat treatment on forgeability is investigated and an improved heat treatment cycle is proposed for the bearing steel, SUJ2. An application example of a bearing inner race cold forging, which has small cracks in the bottom after backward extrusion and piercing, is found from a cold forging industry. The process is evaluated by finite element analysis and several heat treatment cycles are examined in order to propose an improved heat treatment cycle. The effect of heat treatment on material hardness and tool life, dimensional accuracy and forming load is revealed through experiment.

• Transactions of Materials Processing
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• v.6 no.4
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• pp.338-345
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• 1997

The behaviour of alloys in the semi-solid state strongly depends on the imposed stress stage and on the morphology of the phase which can vary from dendritic to globular. To optimal net shape forging of semi-solid materials, it is important to investigate for material behaviour for variation of strain rate. Therefore, to investigate the effect of compression speed on deformation of aluminum alloy with globular microstructure, the compression test for semi-solid aluminum alloy with controlled solid fraction is perform by material test system which is attracted with furance. The behavior of semi-solid aluminum alloy were discussed for the various solid fraction and die speed. The material constants in stress-strain were are also proposed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.365-365
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• 2008

• Transactions of Materials Processing
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• v.19 no.8
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• pp.447-451
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• 2010

In this paper, a useful die system for warm plate forging of a large axle housing of heavy-duty trucks is presented. A die system composed of material flow guide pin as well as upper die and lower die is proposed to reduce the inherent thickness reduction along the bent corner of the product which deteriorates structural strength and fatigue life in its service. The role of the pin assembled in the upper die is to prevent formation of sharp corner in early forming stage and to supply material in the lower die cavity sufficient enough to thicken the bent corner at the final stroke. The mechanism of the die system is given and its effect on corner thickness of the product is revealed by two-dimensional finite element analysis under plain strain assumption. Three-dimensional finite element solutions are also given to verify validity of the two dimensional approach and to show the mechanics of the die system in detail. The die system has been successfully applied to manufacturing the axle housing of heavy-duty trucks.

• Transactions of Materials Processing
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• v.16 no.5 s.95
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• pp.354-359
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• 2007

Effects of forging and mechanical properties of 6061 aluminum alloy wheel for automobiles were investigated in the present study. Microstructural and tensile characteristics of automobile wheel after hot forging process using dynamic screw press were analyzed to evaluate effect of metal flow on mechanical properties. The results showed advanced mechanical properties of 6061 alloy wheel because of $Mg_2Si$ precipitation by T6, elongated grain by forging, and work hardening by dense metal flow, etc. Hot compression tests were conducted in order to characterize high temperature compression deformation behaviors and microstructural variation in the range of $300{\sim}450^{\circ}C$, in the strain rate range of $10^{-3}{\sim}10^1\;sec^{-1}$. As strain rate increased, maximum compression stress increased but it was shown the reverse linear relation between temperature and maximum stress irrelevant to strain rate variation. On the other hand, temperature and yield stress didn't have any linear relation and its relation showed big deviation by a function of strain rate and test temperature.