• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 The 8th Asian Symposium on Precision Forging ASPF
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• pp.143-146
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• 2003

In this paper, a new preform design method is proposed to eliminate the excessive flash in metal forging process. After carrying out finite element simulation of the process with an initial billet, backward particle tracing is performed from the outlet of the flash. Then, the region which belongs to the flash is easily found .. The process is analyzed again with the redesigned billet which is removed that region the above mentioned region. The optimal preform shape which minimizes the amount of flash without changing the forgibility can be obtained in several iterations.

• 한국정밀공학회지
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• 제14권8호
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• pp.82-91
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• 1997

The major objective of this study is to establish analytical technique in order to analyze the behaviour of semi-solid material considering induction heating of the billet. Induction heating process is analyzed by using commerical finite element software. ANSYS. The finite element program, SFAC2D, for the simulation of deformation in semi-solid state is developed in the present study. The semi-solid behaviour is described by a viscoplastic model for the solid phase, and by the Darcy's law for the liquid flow. Simple compression and closed-die compression process considering induction heating are analyzed, and also it is found that the distribution of initial solid fraction of the billet has an important effect on deformation behaviour of semi-solid material. In order to verify the effectiveness of proposed analytical technique the simulation result is compared with experimental result.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2002년도 금형가공 심포지엄
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• pp.225-230
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• 2002

As in most metal forming processes, die and lubrication are of vital importance in hydrostatic extrusion. An efficient die design and lubrication system selection reduce the pressure required for a given reduction ratio by lowering friction at the billet-die interface. In contrast to the conventional macroscopic extrusion, fine-wire fabrication requires higher extrusion pressure and effect of friction is much more significant. Forming fine Au, Ag, and Cu wire with hydrostatic extrusion process in cold condition, the effect of extrusion die angle, lubrication and billet's initial diameter was studied.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 추계학술대회 논문집
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• pp.144-149
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• 1996

In this paper, the clamping type forging of helical gears has been investigated. Clamping type forging is an operation in which the product is constrained to extrude sideways through an orifice in the container wall. Punch is cylindrical shaped. The punch compresses a cylindrical billet placed in a die insert. As a consequence the material flows in a direction perpendicular to that of punch movement. The forging has been analysed by using the upper-bound method. A kinematically admissible velocity field has been developed, wherein, an involute curve has been introduced to represent tooth profile of the gear. Numerical calculations have been carried out to investigate the effects of various parameters, such as module, number of teeth, helix angle, friction factor and initial height of billet on the forging of helical gears.

• 한국군사과학기술학회지
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• 제6권1호
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• pp.68-80
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• 2003

The backward extrusion process of titanium alloy with large length to diameter ratio was simulated for different punch and die shape. The process variables such as initial billet shape, interface friction, contacting time and punch velocity were investigated and compared with experimental results. To make more effectively titanium alloy cup shape forging products with vertical wall, a modified die design which can reduce forging load, prevent sticking with punch and minimize material loss was suggested.

• 소성∙가공
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• 제28권6호
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• pp.347-353
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• 2019

The porthole extrusion process is a classic metal forming process to produce complex cross-section shaped aluminum profile. It is very difficult to design porthole die and extrusion process because of the complex shape of extrusion die and internal metal flow. The main variables in this process are ram speed, initial billet and tool temperature, and die shape. In general, the metal flow of porthole extrusion process can be divided into two steps. During the first step, the billet is divided into several parts in the porthole die bridge. During the second step, the divided billets are welded in the welding chamber. In the welding chamber, the level of welding pressure is very important for the quality of the final product. The purpose of this study is to increase the welding pressure in the welding chamber by using a two stage welding chamber. The porthole extrusion die was designed by using the Taguchi method with orthogonal array. The effectiveness of the optimized porthole die was verified by using the finite element analysis.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2007년도 춘계학술대회A
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• pp.1373-1378
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• 2007

Metal forming ins the process changing shapes and mechanical properties of the workpiece without initial material reduction through plastic deformation. Above all, because of hot working carried out above recrystallization temperature can be generated large deformation with one blow, it can produce with forging complicated parts or heat resisting super alloy such as Inconel 718 has the worst forgeability. In this paper, we established optimal variation of hot heading precess of the Inconel 718 used in heat resisting component and evaluated mechanical properties hot worked produce. Die material is SKD61 and initial temperature is $300^{\circ}C$. Initial billet temperature and punch velocity changed, relatively. Friction coefficient is 0.3 as lubricated condition of hot working. CAE is carried out suing DEFORM software before making the tryout part, and it is manufactured 150 ton screw press with optimal condition. It is known that forming load was decreased according to decreasing punch velocity.

• 대한기계학회논문집A
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• 제36권11호
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• pp.1361-1370
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• 2012

본 논문은 응력 등가정하중을 이용하여 금속제조공정에서 원하는 성형품과 단조품의 최종형상을 얻기 위한 형상최적화 방법을 제안한다. 성형품의 최종형상은 블랭크의 형상에 따라 달라지고 단조품의 최종형상은 빌렛의 형상에 따라 달라진다. 따라서 원하는 형상의 제품을 얻기 위해 구조최적화방법 중 형상최적화방법을 적용하였다. 금속성형 공정은 비선형 동적해석을 수행하므로 등가정하중법을 이용한다. 등가정하중법 중 가상모델을 이용한 응력 등가정하중은 등가정하중을 산출하는 새로운 방법으로 재료 특성의 가치를 재정의하여 응력 등가정하중을 계산한다. 본 논문에 포함된 예제를 통해 원하는 제품의 최종형상을 얻기 위한 최적의 블랭크 및 빌렛 형상을 도출하여 제안한 방법의 유용성을 검증한다.

• 소성∙가공
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• 제26권3호
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• pp.156-161
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• 2017

In this study, the reason of die fracture occurring in hot forging of an aluminum fixed scroll was studied, based on experiments and finite element predictions. The material is assumed to be rigid-viscoplastic, and the die is rigid for the finite element predictions. The stress in the tension at the wrap root is known to cause brittle fracture, and the increase in the tensile stress is owing to the unbalanced filling of material into the die cavities between both sides of the warp. Based on the empirical and numerical achievements, the effects of geometrical parameters of the material on the die fracture were examined to find practical measures for elongated die life. It has been shown from the parametric study that the material with the optimized trapezoidal cross-section, which can be easily made during cutting or the optimized cylindrical billet with its eccentric placement in the die cavity, can considerably reduce the magnitude of the tensile stress around the die corner fractured, indicating that economical manufacturing with reduced number of stages and elongated die life can be realized at once using the optimized practical initial material.

• Design & Manufacturing
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• 제10권2호
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• pp.34-38
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• 2016

In this paper, a transversely isotropic behavior of AZ31 Mg alloy produced by equal-channel angular pressing (ECAP) process was investigated through tensile test and microstructure observation. The effects of initial ECAP pass number on the anisotropic behavior and mechanical properties of the Mg alloy are evaluated after conventional direct extrusion test, which are carried out at a temperature of $200^{\circ}C$. As a result of the tensile test in three directions ($0^{\circ}$, $45^{\circ}$, and $90^{\circ}$ to the extrusion direction of the sheet) at room temperature, elongation of as-extruded AZ31 alloy(ECAP for 0 pass) showed an unusual anisotropic behavior depending on the extrusion direction although the yield strength and tensile strength are similar to the ECAPed AZ31 alloy. After ECAP for 4 passes at $200^{\circ}C$, microstructural observations of ECAPed magnesium alloy showed a significant grain refinement, which is leading to an equiaxed grain structure with average size of $2.5{\mu}m$. The microstructures of the extruded billet are observed by the use of an electron back-scattering diffraction (EBSD) technique to evaluate of the influence on the grain refinement during extrusion process and re-crystallization mechanism of AZ31 Mg alloy.