• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.8 s.179
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• pp.2042-2049
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• 2000

This paper is concerned with the comparison of forging characteristics between forward and backward processes, through the three-dimensional finite element simulation, for the aluminum powder forging of engine pistons. Starting from the theoretical formulation of velocity and temperature fields in the sintered preform during the process, we examine the comparative distributions of relative density, effective stress and temperature as well as the variations of total forging load and total volume reduction. Through the comparative results, we find out that the forward method provides better forging characteristics than the backward method.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.79-83
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• 2008

We carry out three-dimensional simulation of pore closing processes during upsetting in open die forging. Several pores on a plane section of a cylindrical material are traced at the same time and the results of hydrostatic pressure and effective strain are discussed to reveal the parameters affecting pore closing phenomena. Five different sizes of pores are also investigated by simulation to reveal the pore size effect in pore closing during upsetting. AFDEX 3D is employed for this study.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1637-1641
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• 2007

In this paper, we simulate a rotor pole cold forging process by a forging simulator with both tetrahedral and hexahedral element capabilities and compare the predictions obtained by the two approaches with the experiments. Hexahedral element capability runs manually while tetrahedral element capability runs automatically with help of an intelligent remeshing technique. It is shown that the tetrahedral element capability can give quite accurate solution if assisted by the intelligent remeshing technique even though the tetrahedral element itself is not theoretically and numerically clear.

• Transactions of Materials Processing
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• v.4 no.2
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• pp.141-150
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• 1995

The purpose of the open die press forging is to maximize the internal deformation for better structural homogeneity and center-line consolidation in case of the ingot. A two and three dimensional viscoplastic finite element analysis is carried out for the plate, cylinder and square forging with the flat die in order to study the forging effects during the process. Effect of width, height reduction, and die staggering are studied through simulation of the process. Thus favorable working conditions are suggested for better and more disirable product quality.

• Transactions of Materials Processing
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• v.14 no.2 s.74
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• pp.126-132
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• 2005

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 main design priorities were to minimize forging loads and to distribute strain uniformly in a given forging condition. The FE simulation results for the final process design were compared with the isothermal forging tests. The instability of deformation was evaluated using a processing map based on the dynamic materials model(DMM), including flow stability criteria. Finally, a modified process design for producing a uniform Ti-6Al-4V wing product without forming defects was suggested.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.05a
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• pp.145-148
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• 2002

A three dimensional FEM system for supporting the design procedure of metal forming processes has been developed by integrating the FEA programs md the CAD interface modules. The system is developed to reduce the time, the extorts and the cost for establishing the successful metal forming processes for the given products. To promote practical application by engineers in medium-size enterprises who do not know much about theories of the FEA and others, various databases and intelligent interfacing modules have been developed in PC environment.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.3
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• pp.28-35
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• 2016

Forging operations are non-stationary processes occurring because of indirect pressure, generally, under conditions of three-dimensional stress and deformation. Furthermore, due to friction and the constraints of die geometry, deformation is not homogeneous. Material flow and deformation are largely determined by the shape of the tools. It is well known that net-shape forging can improve the mechanical strength of the final product as well as reduce material waste. Oxygen-free copper that is used for electrical and electronic components has excellent electrical and thermal conductivity. Oxygen-free copper parts have a low productivity in cutting process. Thus, the forging process is performed in order to improve the low productivity in cutting process. The forging of oxygen-free copper for electrode body parts was modeled using finite element simulation and forging experiments that were conducted for producing electrode body parts at room temperature. In order to reduce the cost of cutting products, the forging was performed in a closed cavity to obtain near-net or net-shape parts.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.4 s.181
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• pp.37-43
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• 2006

In this paper, an approach to adaptive finite element analysis of three-dimensional forging processes is presented with emphasis on remeshing. In the approach, an optimal tetrahedral element generation technique is employed and the mesh density is specified by the combination of the weighted normalized effective strain and the normalized effective strain rate as well as the weighted normalized curvature. The approach is applied to computer simulation of an enclosed die forging process of a bevel gear and its results are compared with its related experiments. It has been shown that the analyzed results are in good agreement with the experimental ones.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.99-102
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• 2005

An approach to adaptive finite element analysis of three-dimensional forging processes is presented in this paper. In the approach, an optimal tetrahedral element generation technique is employed and the mesh density is specified by the combination of the normalized effective strain and the normalized effective strain rate. The approach is applied to computer simulation of an enclosed die forging process of a bevel gear and its results are compared with experiments.

• Transactions of Materials Processing
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• v.15 no.3 s.84
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• pp.189-194
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• 2006

In this paper, an automated adaptive mesh generation scheme, based on an advancing-front-Delaunay method, is presented fur finite element simulation of three dimensional bulk metal farming processes. Basic approach is introduced in detail, including a surface meshing and volume meshing technique and a mesh density control scheme. The presented approach is applied to automatic forging simulation in order to evaluate the effect of the developed schemes. Comparison shows a good agreement between required mesh density and generated mesh density, implying that the presented approach is appropriate for automatic mesh generation in metal forming simulation.