• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.341-344
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• 2009

Large load is required in forging of large-scale components, which becomes a critical restriction in practice. However, the load can be greatly reduced by adopting incremental forging technologies. In the present study, two methods of incremental forging were investigated for the purpose of reducing the load required. One was to use nine strokes with a flat die and the other was to use three strokes with a curved die. The die moves vertically in the former while it moves vertically as well as rolls horizontally in the latter. Deformation of the slab in each case was analyzed by rigid-plastic finite element method and as a result, variations of load and distributions of effective strain were predicted.

• Transactions of Materials Processing
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• v.18 no.7
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• pp.513-518
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• 2009

Large load is required in forging of large-scale components which becomes a critical restriction in practice. In the present study, two methods of incremental forging were investigated for the purpose of reducing the load required for forging of large and thick plates. The forging was applied primarily to obtain fine grains by imposing large amount of plastic deformation to the plates. One was to use nine strokes with a flat die and the other was to use three strokes with a curved die. The die moves vertically in the former while it moves vertically as well as rolls horizontally in the latter. Deformation of the slab in each case was analyzed by rigid-plastic finite element method and as a result, variations of load and slab holding force, and distributions of effective strain and thickness were predicted.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.95-98
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• 2005

Shafts having asymmetry or odd number of symmetry in the cross-section can not be simply manufactured by conventional incremental radial forging. In order to manufacture such shafts, the new concept of incremental forging with one punch and a flexible fixture is developed by suggesting a flexible fixture, instead of two opposed punches used in radial forging, so that the flexible fixture only supports the workpiece while the punch is moving during forming. A new flexible fixture is designed using the steel shots and vacuum technology. An equilateral triangular cross-section is selected as the sample shape to be manufactured by the proposed manufacturing method. The desired triangular cross-sectional shaft is manufactured with the errors of $3.0\%$.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.7
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• pp.1685-1696
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• 1994

In this paper, a new forming process of the large-size forgings within the limit of forming loads is developed by introducing the incremental forging method and combined forming method. For the development of the forming process, various related processes are proposed and modelling experiments of plasticine and corresponding numerical simulation ate carried out. Thus, an optimal process considering the productivity and economical efficiency is recommended from the study of formability and forming loads, etc. The selected process is subjected to a modelling experiment of lead and 1/7 scale prototype experiment of the real material so as to verify the effectiveness of a selected process as well as to determine the design parameters. The developed process is then applied the forging product of dome shape. Dome-shaped forgings can be produced by the developed process within the limit loads and with the simple tools.

• Transactions of Materials Processing
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• v.3 no.1
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• pp.110-119
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• 1994

In this paper, a new forming process of large-size forgings of converged nozzle-shape is developed by the experimental study using the incremental forging method and combined forming method. The development of the forming process is focused on the manufacturing of large-size forgings by the press with medium load capacity. Various related processes are proposed and modelling experiments using plasticine are carried out. Thus, the incremental forging method for expanding is recommanded from the study of formability and forming load, etc. The selected process is then subjected to modelling experiments of lead and the design parameters such as preform for final process, die-width of the upper die and reduction amount of each stroke are determined. In order to verify the effectiveness of the selected process, 1/7 scale prototype experiment of the real material is carried out. Forgings of converged nozzle shape can be produced by the developed process within the limit loads and with the simple tools.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.812-815
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• 2005

The incremental forming process employs several tens or hundreds of continuous local strokes, so the entire process is difficult to analyze due to much computation time and large computer memory. The objective of this work is to propose a new numerical scheme of the finite element method, automatic expansion of domain (AED), and to reduce computation time and computer memory. In the AED scheme, an effective analysis domain in each local forming step is defined and then the domain is automatically expanded in accordance with the repeated process. In order to verify the validity of the criterion for the AED scheme and the applicability of the AED scheme, two-dimensional incremental plane-strain forging process is first analyzed using the proposed scheme with various criteria and full domain. In addition, three-dimensional incremental radial forging process is analyzed to verify the applicability of the proposed scheme to a practical incremental forging process.

• Transactions of Materials Processing
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• v.22 no.8
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• pp.463-469
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• 2013

In the previous work, a new forging process design, which included incremental upsetting, diffusion bonding and cogging, was suggested as a method to manufacture 1.9wt%C ultrahigh carbon workrolls. The previous study showed that incremental upsetting and diffusion bonding are effective in closing voids and healing of the closed void. In addition, compression tests of the 1.9wt%C ultrahigh carbon steel revealed that new microvoids form within the blocky cementite at temperatures of less than $900^{\circ}C$ and that local melting can occur at temperatures over $1120^{\circ}C$. Thus, the forging temperature should be controlled between 900 and $1120^{\circ}C$. Based on these results, incremental upsetting and diffusion bonding were used to check whether they are effective in closing and healing voids in a 1.9wt%C ultrahigh carbon steel. The incremental upsetting and diffusion bonding were performed using sub-sized specimens of 1.9wt%C ultrahigh carbon steel. The specimen was deformed only in the radial direction during the incremental upsetting until the reduction ratio reached about 45~50%. After deformation the specimens were kept at $1100^{\circ}C$ for the 1 hour in order to obtain a high bonding strength for the closed void. Finally, microstructural observations and tensile tests were conducted to investigate void closure behavior and bonding strength.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.5
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• pp.1166-1180
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• 1990

The study is concerned with the two-dimensional thermo-viscoplastic finite element analysis for radial forging as an incremental forging process. The deformation and temperature distribution of the workpiece during radial forging are studied. The analysis of deformation and the analysis of heat transfer are carried out for simple upsetting of cylinder by decoupling the above two analyses. A method of treatment for heat transfer through the contact region between the die and the workpiece is suggested, in which remeshing of the die elements is not necessary. Radial forging of a mild steel cylinder at the elevated temperature is subjected to the decoupled finite element analysis as well as to the experiment. The computed results in deformation, load and temperature distribution are found to be in good agreement with the experimental observations. As an example of viscoplastic decoupled analysis of hot radial forging, forging of a square section into a circular section is treated. The stresses, strains, strain rates and temperature distribution are computed by superposing material properties as the workpiece is rotated and forged incrementally. It was been thus shown that proposed method of analysis can be effectively applied to the hot radial forging processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.353-358
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• 2006

A three-dimensional finite element approach to process analysis and design for joining the socket with the ball by a kind of the rotary forging processes is presented in this paper. The rigid-plastic finite element method is employed and its results are used to reduce the number of process design tryouts. The approach is applied to developing a concave piston assembly for a high pressure hydraulic pump. Experiments show that the developed piston assembly satisfies the quality requirement on geometrical tolerance.

• Transactions of Materials Processing
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• v.21 no.4
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• pp.234-239
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• 2012

This study examines the forming properties and forming loads needed to increase the edge thickness on the external face of a plate using finite element analysis(FEA). Recently, forming optimization techniques within FEA are being extensively used in designing the optimal forming conditions for processes like forging, extrusion, rolling, and spinning. Most of these existing forming operations involve reducing the volume per unit length, but research for increasing volume per unit length is not very extensive. For this study we chose an automotive engine flywheel which is a welded assembly of a plate and a gear with each component having a different thickness. We considered a forming technique to increase the thickness in order to allow the machining of the gear directly on the external face of plate alleviating the need for a weld. To study various forming techniques, we used the finite element method with the flow stress of material and incremental forming steps. We conclude from this study that the analysis of forming properties and forming loads by using the finite element analysis and testing is useful as a method to increase the thickness per unit length.