• Journal of the Korean Society for Precision Engineering
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• v.21 no.1
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• pp.32-39
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• 2004

Traditional forging of a hollow T-shaped part has been applied to forge a solid T-shaped product from a solid billet and then to machine the hollow in that. In a case, a hollow T-shaped part can be forged by backward-extruding from a solid billet. In this study, four types of forging were suggested for manufacture of hollow T-shaped parts. Forging simulations for each of these forging methods were carried out to investigate folding defect, metal flow pattern, effective strain, and forging loads. Experimental works were carried out to be compared with the simulation results. Here, the ratio of the thickness of the hollow tube to that of the flange was selected to investigate a forging defect like folding.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.10a
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• pp.190-190
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• 2003

동력 전달용 구동부품에 있어서 중공 플랜지 형상의 부품은 흔히 찾아 볼 수 있으며, 이는 높은 강도를 요구하기 때문에 강도향상을 위하여 단조에 의한 제품의 성형 방법이 많이 연구되고 있다. 중공 플랜지형상을 갖는 제품의 제조 방법으로서는 중실 플랜지 형상으로 단조하여 내경부를 절삭가공하는 방법, 중실 소재를 후방압출하여 중공 플랜지형상으로 단조하는 방법, 또는 중공의 초기소재를 사용하여 중공 플랜지형상으로 단조하는 방법이 일반적이다. 본 연구에서는 Fig. 1에 나타낸 것과 같이 중공 플랜지 형상을 갖는 기계 부품의 단조방법에 대해 연구하였으며, 중공 관의 내경을 $d^1$, 외경을 $d^2$, 플랜지부의 외경을 $D^0$, 중공 관의 두께를 t, 플랜지부의 두께를 T로 정의하였다. 중공 플랜지 형상에 있어서 공정 설계의 변수는 다양하겠으나, 본 연구에서는 중공관의 외경과 내경의 형상비 $\alpha$(=$d^2$/$d^1$), 플랜지의 폭과 중공관의 두께비 $\beta$(=B/t) 및 중공관의 두께와 플랜지의 두께비 r(=T/t)의 변화에 따른 성형조건에 관해 고찰하였다. 중공 플랜지 형상의 성형방법으로 Fig. 2에 나타낸 것과 같은 $\circled1$중실소재를 이용한 후방압출단조(backward extrusion forging)방법, $\circled2$중공 소재를 이용한 엎셋(upset forging)방법, $\circled3$중공 소재를 이용한 압조법(injection forging), $\circled4$중실소재를 이용한 압조-압출(injection-extruding forging)법의 4가지의 단조 방법을 제시 하였다. 또한, 유한요소해석을 수행하여 소성유동 형태, 유효변형률, 단조하중을 검토하고. 모델재료인 납을 이용한 실험을 통하여 이를 검증하였다. 이를 바탕으로 산업 현장에서 경험에 의존하였던 공정 설계를 보다 효과적으로 개선하기 위한 단조법을 제시하고자 하였다. 또한 중실 소재를 이용한 중공 플랜지 형상의 단조 방법 중 보다 적절한 단조방법인 압조 단조에 있어서 일반적으로 사용되고 있는 SM10C에 대한 유한요소 해석을 수행하였으며, 제품의 형상비에 따라 폴딩 결함의 발생 유무를 검토하고, 폴딩 결함 없이 단조하기 위한 중공 플랜지의 형상한계 비를 제시하였다.

• Journal of Welding and Joining
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• v.20 no.3
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• pp.98-104
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• 2002

A study on microstructures of welds for Zircaloy-4 sheath end closure by the resistance upset welding methods was carried out. Two upset welding process variations such as magnetic farce and multi-impulse resistance welding were used. Grain size and microhardness across welds were analysed in terms of welding parameters. Magnetic farce resistance weld with one cycle of unbalanced mode has smaller upset length and $\alpha-grain$ size in heat affected zone than those of multi-impulse resistance weld because of lower heat input and shorter welding time. Heat affected zone formed by two upset resistance welding variations revealed fine Widmanstatten structure or martensitic ${\alpha}'$ structure due to the high heating rate and foster cooling rate. Magnetic force resistance welds showed recrystallized grains before grain growth, whereas multi-impulse resistance welds showed full grain growth.

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.4
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• pp.535-540
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• 1986

본 연구에서는 소재의 3차원 변형, 즉 평면변형(sidewise spread)과 벌징변형 을 동시에 고려할 수 있는 간단한 동적가용 속도장을 제안하고 이를 클로버(clover) 시편의 업세팅 단조 해석에 적용해보기로 한다. 상계이론에 의한 전체 에너지 소비 율을 최소화시키면서 그때 그때의 높이 감소에 따른 단조 하중과 변형 형상을 구한다. 실험은 SM15C 탄소강을 이용하여 시편의 형상과 윤활조건을 바꿔가면서 상온에서 수행 한다.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.98-101
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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 imperfection 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 it is for better control of forming operation we should necessarily find out their phenomena. In this study we used the friction disturbance due to inclined punch angle and introduced the method considering kinematic hardening effect Analysis of upset forging is carried out using the rigid plastic FEM and slab method with eccentricity.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.6
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• pp.75-81
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• 2012

Dissimilar material friction welding such as STD11 and SCM440, we are considering of such things as strength and tenacity of welding interface, which consist of friction welding rotation frequency, friction heating pressure, upset forging-pressure, friction heating time, and upset forging-pressure time. From the study, obtaining the interrelationship between welding condition and quality(toughness, tenacity), we can set the best range of welding condition. while performing acoustic emission examination for the nondestructive evaluation, we can deduce the interrelationship among total acoustic emission counts, friction welding variable, and quality during friction welding, which can solve the manufacturing difficulty and enhance the economic value.

• Transactions of the Korean Society of Mechanical Engineers
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• v.19 no.6
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• pp.1539-1544
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• 1995

Copper blow test to measure the forging capability of 35 ton counterblow hammer and upset of plasticine on the model hammer to investigate the change of the blow efficiency during the forging process have been performed together with finite element analyses of these experiments. The blow efficiency of the hammer has been found to be dependent on the friction and on the contact area between the die and the workpiece. The effects of the volume and the aspect ratio of the billet have not been found. Inferring from the experimental results and Schey's empirical formula on the forging load, we expect that the efficiency also varies with the flow stress of the workpiece material and with the shape complexity of the forging product.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.04a
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• pp.206-211
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• 1996

Closed-die forging of external spine is analysed using an upper bound elemental technique. The kinematically admissible velocity field for three-dimensional deformation in forging of the external spine with trapezoidal teeth was obtained. The upper bound to the deforming load necessary and the the deformed configurations are predicted using integration of the formulation of energy expressions which were obtained from B(upset forging method) were considerd in the present analysis and the theoretical results compared with experimental ones Experiments were carried out on plasticine as model material at room temperature where talcum powder was used as a lubricant. The present investigation revealed that the analytical method B predicts a reducet forging load and improved configuration better than method A for the forged products.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.277-280
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• 2005

A shape optimization is applied to achieve a design objective in three-dimensional forging processes. In multi-stage forging processes, among the important design aspects, the die shape fur preforming is regarded as the design variable since it influences the forged part relatively higher than the others. The rigid-plastic finite element method and the sensitivity method are employed and formulated to solve a formulated optimization problem. An approximation scheme is also used for the direction search during the optimization. The upset forging of a square box is selected as a test example in order to demonstrate and verify the optimization process of this study. After the optimization, the optimized shape of the die yields a finial product of desire shape.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.210-216
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• 1994

The velocity fields can be composed by nodal points using shape function. Forging load and deformed profile are obtained by minimizing total energy consumption rate which is function of unknown velocities at each nodal points. The velocity and stremiline distribution can also be investigated at the deformation profile. The effectiveness of proposed method in this paper is demonstrated by comparing with those of FEM and experiment, that is the results of upset forging problem. Obtained results are compared with FEM and experiment and fairly good agreement is found between them.