• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1997년도 춘계학술대회 논문집
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• pp.837-841
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• 1997

An upper bound elemental technique(UBET) program has been developed to analyze forging load, die-cavity filling and optimum kinematically admissible velocity fields for flashless forging. The simulation for flashless forgings are applied plane and axisymmetric closed-die forging with rib-web type cavity. The kinematically admissible velocity fields for inverse triangular and inverse trapezoidal elements, are used to analyze flashless forging. Experiments have been carried out with pure plasticine billets at room temperature. Theoretical predictions of the forging load in plane-strain and axisymmetric forging are in good agreement with experimental results.

• 한국정밀공학회지
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• 제12권10호
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• pp.57-68
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• 1995

An upper bound elemental technique (UBET) program has been developed to predict forging load, die-cavity filling, preform in non-axisymmetric forging. To analyze the process easily, it is suggested that the deformation is divided into two different parts. Those are axisymmetric part in corner, plane-strain part in lateral. The plane-strain and axisymmetric parts are combined by building block method. And the total energy is computed through combination of three deformation parts. A dumbbell-type preform has been obtained from height and volumetric compensations of the billet based on the backward simulation. Experimetns have been carried out with pure plasticine at room temperature. Theoretical predictions are in good agreement with expereimental results.

• 한국정밀공학회지
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• 제10권4호
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• pp.109-117
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• 1993

Force balance method is employed to predict forging information such as forging load, tool pressure and normal stress at the surface of tangential velocity discontinuity. The incipient stages of deformation for the plane strain forging of rectangular billets in V-shaped dies of different semi-angles are analysed. To construct an approximate model for the analysis of deformation by the force balance method in the incipient deformation stages, slip-line field is used. When the deformation mode by slip-line method is the same as that by force balance method, the slip-line method and the force balance method give identical solutions. The effects of die angle, coefficient of friction, billet geometries and deforma- tion characteristics are also investigated. In order to verify the validity of force balance analysis, the rigid-plastic finite element simulation for the various forgig parameters are performed and performed and find to be in good agreement.

• 소성∙가공
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• 제19권7호
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• pp.399-404
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• 2010

We propose an analysis model for simulating the detailed procedure of pore closing in open die forging of shafts. In the analysis model, an artificial symmetric plane is used, on which initial pores are located to be traced. The analysis model is employed to carry out three-dimensional simulation of pore closing in shaft free forging by both conventional free forging press and radial forging machine. With this result, two typical types of free forging equipment for manufacture of shafts are compared in detail. It has shown that the radial forging machine is much superior to the conventional open die forging press especially in pore closing under high hydrostatic pressure with sound strain.

• 한국분말재료학회지
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• 제4권2호
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• pp.83-89
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• 1997

A finite element analysis to solve the coupled thermomechanical problem in the plane strain upsetting of the porous metals was performed. The analysis was formulated using the yield function advanced by Lee and kim and developed using the thermo-elasto-plastic time integration procedure. The density and temperature dependent thermal and mechanical properties of porous metals were considered. The internal heat generation by the plastic deformation and the changing thermal boundary conditions corresponding to the geometry were incorporated in the program. The distributions of the stress, strain, pressure, density and temperature were predicted during the free resting period, deformation period and dwelling period of the forging process.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 추계학술대회 논문집
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• pp.354-357
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• 2005

When Ti-6Al-4V is used in long steam turbine blades, the main issues are how to improve the fatigue strength as a problem of internal quality and how to forge the thinnest possible blades as problem of dimensional precision. To assure an excellent fatigue strength, it is important to make the two phase fine and equiaxial structure by providing enough plastic deformation in the two phase$(\alpha\;phase/\beta\;phase)$ temperature region. Accordingly, it needs to predict that forging temperature, preform design and forging velocity in forging process. To achieve this end, the two steps forging process was suggested to forge the thin and twisted blades with a precision hammer considering die forces and metal flow. Two steps forging process consists of the flattening forging process and finishing forging process. Process in forging of a 1016mm long steam turbine blade is designed by the finite element method. This study attempts to derive systematic design procedures for process design in the forging. Forging parameters was analyzed in two-dimensional plane-strain simulation and two steps forging process carried out in three-dimensional simulation. Consequently, optimal forging process parameters of long steam turbine blades in Ti-6Al-4V with a high dimensional precision are selected in the hammer die forging.

• 한국분말재료학회지
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• 제2권1호
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• pp.19-28
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• 1995

Powder forging is a combined technology of powder metallurgy and precision hot forging. Recently, the technology is developing rapidly because of its economic merits, especially in automotive part manufacturing. In the present study, the finite element technique was developed to predict density variation during P/M forging and the technique was applied to analysis of forging of a P/M connecting rod. Although deformation mode of the connecting rod was quite complex, several sections were selected and analyzed under an assumption of asymmetric or plane strain deformation. It was found that some modifications were necessary on the cross section of the beam portion. Therefore, the cross section was modified repeatedly until a satisfactory result of the analysis was obtained. On the other hand, no modifications were necessary in the ring and the pin portions. It is anticipated that the developed technique can be used to optimize preform design and manufacturing processes in P/M forging, which are highly critical to produce successful products in practice.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2004년도 춘계학술대회 논문집
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• pp.190-193
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• 2004

Ever since the ideal forming theory has been developed fur process design purposes, application has been limited to sheet forming and, for bulk forming, to two-dimensional steady flow. Here, application for the non-steady case was performed under the plane-strain condition based on the theory previously developed. In the ideal flow, material elements deform following the minimum plastic work path (or mostly proportional true strain path) so that the ideal plane-strain flow can be effectively described using the two-dimensional orthogonal convective coordinate system. Besides kinematics, for a prescribed final part shape, schemes to optimize a preform shape out of a class of initial configurations and also to define the evolution of shapes and boundary tractions were developed. Discussions include the two problematic issues on internal tractions and the non-monotonous straining. For demonstration purposes, numerical calculations were made for a bulk part under forging.

• Fibers and Polymers
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• 제3권3호
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• pp.120-127
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• 2002

Ever since the ideal forming theory has been developed for process design purposes, application has been limited to sheet forming and, for bulk forming, to two-dimensional steady flow. Here, application for the non-steady case was made under the plane-strain condition. In the ideal flow, material elements deform fellowing the minimum plastic work path (or mostly proportional true strain path) so that the ideal plane-strain flow can be effectively described using the two-dimensional orthogonal convective coordinate system. Besides kinematics, schemes to optimize preform shapes for a prescribed final part shape and also to define the evolution of shapes and frictionless boundary tractions were developed. Discussions include numerical calculations made for a real automotive part under forging.

• 소성∙가공
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• 제27권5호
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• pp.276-280
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• 2018

This paper has developed a forging process for conical shells for making aluminum cylindrical large shells. An incremental forging process was applied to reduce forging loads and die cost. The preform is designed based on the crosssectional area of the final forged shape. Inner diameter of the preform for mandrel forging is constant, and outer diameter is conical so that it matches the cross-sectional area of the product. However, simulation confirmed that the larger diameter is smaller than predicted and the length is larger than predicted because in the initial stage of forging, the large diameter portion first comes into contact with the anvil at the initial stage of forging and stretches in longitudinal direction. So, it has developed a rule to design the preform considering 3-D deformation instead of plane strain deformation at the beginning stage of mandrel forging. The developed mandrel forging process can be applied to more similar products and economic benefits may be obtained.