• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.170-175
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• 2007

The finite volume method for forging simulation is examined to reveal its possibility as well as its problem in this paper. For this study, the finite volume method based MSC/SuperForge and the finite element method based AFDEX are employed. The simulated results of the homogeneous compression obtained by the two softwares are compared to indicate the problems of the finite volume method while several application examples are given to show the possibility of the finite volume method for simulation of upsetter forging processes. It is shown that the finite volume method can not predict the exact solution of the homogeneous compression especially in terms of forming load and deformed shape but that it is helpful to simulate very complex forging processes which can hardly be simulated by the conventional finite element method.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.1
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• pp.152-157
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• 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 Materials Processing
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• v.17 no.2
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• pp.113-116
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• 2008

Computer simulation of microstructure evolution during hot forging process is of great interest in recent years. Recrystallization model and grain growth model which use a phenomenological approach were summarized. The upsetting and cogging processes of waspaloy were simulated using $DEFORM^{TM}$ and the change in grain size were investigated in each deformation procedure.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.53-56
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• 2007

Computer simulation of microstructure evolution during hot forging process is of great interest in recent years. Recrystallization model and grain growth model which use a phenomenological approach were summarized. For the waspaloy, upsetting process and cogging process were simulated using $DEFORM^{TM}$ and the change in grain size were investigated in each deformation procedure.

• Transactions of Materials Processing
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• v.8 no.2
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• pp.216-221
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• 1999

In this paper, an application-oriented approach to piercing analysis in automatic forging simulation by the rigid-viscoplastic finite element mehtod is presented. In the presented approach, the accumulated damage is traced and the piercing instant is determined when the accumulated damage reaches the critical damage value. A method of obtaining the critical damage value by comparing the tensile test result with the analysis one is given. The presented approach is verified by experiments and applied to automatic simulation of a sequence of 6-stage forging processes.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.1
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• pp.92-99
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• 2003

Bevel gears are important mechanical parts to transmit power in transportation system high precision parts like bevel gears might be manufactured by closed die forging process for dimensional accuracy. Closed die forging of bevel gears offers the high quality and good mechanical properties and also leads to considerable cost saving. To determinate the proper closed-die forging process for bevel gear forms, three-dimensional finite element simulation for the progressive forging process was earned out and also the simulation results were compared with experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.175-178
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• 2003

Tool life in cold forging is influenced by tool quality as well as forging conditions and quality of forging material. This paper presents some typical examples of tool life improvement in aspect of tool quality depending on tool design and tool manufacturing parameters. For the purpose of improving tool life, suggestions should be based on accurate understanding of tool operating conditions in cold forging process. FE simulation known as CAE is effective in order to make clear the conditions by some numerically calculated result.

• Transactions of Materials Processing
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• v.16 no.4 s.94
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• pp.288-292
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• 2007

This study focuses on the warm forging of a magnesium alloy impeller used for the fuel cell. The impeller has the very complicated shape with sharply twisted blade and thus is generally produced by mechanical machining or casting process. However, since these technologies give the high manufacturing cost or poor mechanical properties, the forging technology is required to make the high-quality impeller with the lower manufacturing cost. In order for production of the impeller by warm forging technology, the parametric studies using finite element analyses were carried out to find the optimal perform shape of impeller. Based on the FE simulation results, dies for impeller forging were designed and the resultant forged impeller was shown.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.10
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• pp.51-57
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• 1998

In this paper, a computer aided process design technique, utilizing a forging simulator and a commercial CAD software, is presented together with its related design system for cold-former forging of ball joints. The forging sequence design is carried out through user-computer interaction by using design templates, design database, experience or knowledge-based rules and some basic laws found in the literature. The forging simulation technique is used to verify the process design. The detail designs including die set drawings and die manufacturing information are automatically generated. It has been shown that the engineer ing and design productivity is much improved by the presented approach in the practical standpoint of process design engineers.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.183-188
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• 2007

We simulated a hot forging process for the spider with four legs and an enclosed die forging process for the spider with three legs using an intelligent forging simulator AFDEX 3D and compared the predictions with the experiments in terms of the deformed shape. The formation of characteristic lines was emphasized in the simulation to simulate the extruded legs with higher accuracy.