• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.1101-1104
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• 2004

A brake spider in an irregular shape, which is used as a part in the braking system of a vehicle like a big truck and a trailer, is subjected to a large torque and hence requires both strength and endurance over the brake heat. Manufacture of this product in practice is generally composed of hot forging processes and machining. At the present study, two or more processes were considered for the hot forging. With an initial circular billet, blocker and finisher processes were analyzed using the rigid-plastic finite element method and also in addition to the preforming process. Proper forging processes to manufacture an irregular product without forging defects, which are preforming, blocker and finisher, were discussed and commented upon.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1995.03a
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• pp.62-70
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• 1995

The inner pulley is automobile component used as airconditioner clutch assembly. in cold forging of the inner pulley . the design conditions are the same between inner length and outer length, the uniform hardness and the no shape change in inner fillet radius due toa piercing. In industries, the design of forging processes is performed based on an experience-oriented technology, that is, designer's experiences and expensive trial and error. Using the rigid -plastic finite element simulation, we propose the optimal process conditons and design of preform or redesign of final product shape without defects prodicted by metal flow, distribution fo strain, forging load during forging processes form initial workpiece to final product.

• Proceedings of the KSME Conference
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• 2008.11a
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• pp.1113-1118
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• 2008

In the hot forging process, The forging defects that are caused by metal were strain, temperate, and inclusion. In this paper, the computer simulation analyzed the effective plastic strain and temperature behaviors. The quantitative analyses which proposed the effective mold design of S/CAM shaft was executed. The parameters of forging shape that affected on the optimize conditions that was calculated with simple equation were investigated. it is expected that the developed analysis model and design technique would greatly contribute to the drum brake optimal design considering temperature affected and material behaviors. This development could save more than 20% of production cost and reduced failure rate to more than 30%. By improving the life span of mold from 15,000 to 25,000, financial difficulty of company imposed on a mold manufacture could be overcome.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.190-194
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• 2007

The forging process design and microstructure evolution for gas turbine disk of a Waspaloy is investigated in this study. Parameters related to deformation are die and preform geometry, and forging temperature of die and workpiece. Die and preform design are considered to reduce the forging load, and to avoid the forging defects. Blocker and finisher dies for multistage forging are designed and the initial billet geometry is determined. The control of hot forging parameters such as strain, strain rate and temperature also is important because the microstructure change in hot working affects the mechanical properties. The dynamic recrystallization evolution has been studied in the temperature range 900-$1200^{\circ}C$ and strain rate range 0.01-1.0s-1 using hot compression tests. Modeling equations are required represent the flow curve, recrystallized grain size, recrystallized volume fraction by various tests. In this study, we used to thermo-viscoplastic finite element modeling equation of DEFORM-2D to predict the microstructure change evolution during thermo-mechanical processing. The microstructure is updated during the entire thermal and deformation processes in forging.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.114-117
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• 2004

The isothermal forging design of a Ti-6Al-4V wing shape was performed by 3D FE simulation. The design focuses on near-net shape forming by the single stage. The process variables such as the die design, pre-form shape and size, ram speed and forging temperature were investigated. The minimization of forging load and uniform strain distribution in a given forging condition were considered as main design factors. The FE simulation results fur the final process design were compared with the isothermal forging tests. Finally, the modified process design for producing the uniform Ti-6Al-4V wing product without forming defects was suggested.

• 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.

• Transactions of Materials Processing
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• v.8 no.4
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• pp.393-398
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• 1999

The plastic instable flow phenomenon happens in practical forming process, I. e. upsetting, backward extrusion, piercing, indentation. And also, it is difficult to control precisely the shape and dimensions of forming process. It is found that instabilities of the process are mainly connected with imperfections in the lubrication, billet eccentricity, inclined punch alignment. In view of the direct relationship between instable material flow and quality defects of the products and for better control of forming operation, we should necessarily find out their phenomena. In this study, we introduced the friction disturbance due to inclined punch angle. Analysis of upset forging is carried out using the rigid plastic FEM and slab method with eccentricity. Also, we considered the buckling parameters of billet with the large aspect ratio in upset forging.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.106-110
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• 2001

A effective and accurate method of hot-forging process is essential to the design of optimized dies as well as workpiece of intial shape. the former is achieved by a proper forging sequence with invokes serious problem like excessive load and die wear, die failure, underfilling and lap defects. the latter is achieved by a proper preform design of case I, case II, case III. metal forming processes of aluminum-alloy forged at an effective strain and temperature are analyzed by the finite element method. the non-isothermal analysis have been compared with optimized in terms of preform shape.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.1
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• pp.67-73
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• 2011

In this study, the manufacturing technology of a folding blind rivet was developed through finite element analysis(FEA). Numerical simulations of the folding blind rivet used to join two components have been performed with the finite element method for the forging process design. To minimize the process and manufacture the folding blind rivet without defects, a variety of design rules were proposed. From the results of FEA applied process design rules, an optimal six-stage process was proposed. The finite element simulation results such as shape of the forged rivet, strain distribution and forging load were investigated for the usefulness of the forging process of the blind rivet. In addition, the experiments have been implemented and their results were compared to the analytic results.

• Transactions of Materials Processing
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• v.18 no.8
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• pp.589-595
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• 2009

The hot forming process of an exhaust CAM for vessel engine was designed by finite element(FE) simulation and experimental analysis. An aim of process design was to achieve the near-net shaped CAM forgings by hot forging process. Based on the compression test results of the low alloy steel, power dissipation map was generated using the the dynamic materials model(DMM). From the map, the initial heating temperature was determined as 1200oC. FE analysis was simulated to predict the formation of forging defects and deformed shape with different forging designs. Optimum process design suggested in this work was made by comparing with the CAM for vessel engine manufactured by actual forging process.