• Transactions of Materials Processing
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• v.17 no.2
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• pp.124-129
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• 2008

Net shape forging technologies give many effects into the costs and qualities for the finished products. So, the studies to reduce the additional machining amount are very important in forging industry. Specially, there are two main topics in cold forging industry, such as, tool life and precision forging. In this study, new forging technique was proposed to eliminate the machining process for fixing up the length and improve the lead accuracy of gear. The luck-up hub is manufactured through many processes, such as upsetting, piercing and direct extrusion. The gear is formed in direct extrusion process; however, lead accuracy of the gear is over allowance limit. Therefore, the additional sizing process must be added. In this study, process design for closed-die forging of a lock-up hub used for a component of automobile transmission was made using three-dimensional finite element simulations, and the strain distributions and velocity distributions are investigated through the post processor. The rigid-plastic finite-element method for back pressure forging has been used in order to reduce development time and die cost. Using the FEM simulation, we found the optimum value of back pressure. The prototypes of lock-up hub parts were forged into the net-shape. In the experiment, lead precision of tooth are measured by the CCMM(Contact Coordinate Measuring Machine). The dimensional accuracy of forged part was improved up to the 40% when back press was applied.

• Journal of Ocean Engineering and Technology
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• v.2 no.2
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• pp.112-121
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• 1988

A study on friction welding of carbon steel bar (SM45C) to chrome molybedenum steel bar(SCM4) is examined experimentally through tensile test, hardness test, microstructure test and fatigue test. so, this paper deals with optimizing the welding concitions and analyzing various mechanical properties about friction welds of SM45C to SCM4 steel bars. The results obtained are summarized as follows; 1) For friction welded joints of SM45C to SCM4 steel bars, the total upset(U)increases linearly with an increase of heating time ($t_{1}$) till 6s. 2) The determined optimum welding conditions are heating time ($t_{1}$)2s, upsetting time($t_{2}$), 3s, heating pressure($p_{1}$), 4kgf/$mm^{2}$(39.2MPa), upsetting pressure($p_{2}$, 8kgf/mm$^{2}$(78.4MPa) and rotating speed(N), 2, 000rpm when the total upset(U) is 3.4mm, resulting in a computed relationship between the joint tensile strength .sigma.$_{t}$ (kgf/mm$^{2}$and the total upset U(mm); .sigma.$_{t}$ =$0.21U^{3}$ - $3.38U^{2}$ +17.03U + 66.00 3) As the elongation is increased more and more, the fracture position becomes away from weld interface and the fractures are similar to those of SM45C. Fracture is taken place on SM45C side. 4) The weld interface of two dissimilar materials is mixed strongly, and the heat affected zone is about 2.0mm at SM45C while about 2.7 mm at SCM4 side. Therefore, the welded zone and heat affected zone are very narrow, comparing with those of the joints welded by the other welding methods. 5) The fatigue strengths at N=10$^{6}$ cycles of SM45C, SCM4 and friction welded joints are 23kgf/$mm^{2}$, 33kgf/$mm^{2}$(220.5 MPa), and 22.5kgf/$mm^{2}$(220.5MPa) respectively, and fracture at friction welded joint takes place at the side of SM45C. 6) The hardness of the friction weld interface is 3 times higher than that of base metal. 7) Fatigue strength of friction welded joint is higher than that of base metal. 8) Notch sensitivity factor of friction welded joint is lower than that of base metal.

• Journal of the Korean Society of Clothing and Textiles
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• v.31 no.5 s.164
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• pp.729-741
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• 2007

In order to examine the characteristics of brassiere products for the 1924 generation brands on the market and grasp problems, we selected three 'comparative brassieres', each one from among the 1924 underwear brands with the highest recognition and sales profit, and then designed a 'sample brassiere' pattern(75A) with a similar shape to the comparative brassieres. We set up the "New Cup Grading Rule" with a view of reflecting the wearing effect that was varied according to cup sizes, graded the sizes of 75AA and 75B with this method, and made the sample brassieres in three sizes. We conducted the wearing evaluation and body measurements of 9 subjects after analyzing the patterns and characteristics of the sample brassieres and three comparative brassieres. As a result of the wearing evaluation, the sample and comparative brassiere 2, the dimensions and shapes were appropriate for the 1924 generation consumers and expressed an overall natural silhouette, showed satisfactory results in the entire evaluation questions. On the other hand, the comparative brassiere 1 and 3 that tended toward making a big change in the physical characteristics got unsatisfactory evaluations in the dimensions of the cups, clothing pressure, and bust silhouette. As a result of observing the variation in body dimensions by body measurements when nude and when wearing each brassiere and then summing it up with the score of the wearing evaluation, it was proven that too much change in body shape can create a negative image by upsetting the balance of the whole silhouette. Therefore, it is desirable to develop brassiere products with proper dimensions and clothing pressure that can make a physical change that harmonizes the overall bust silhouette and the position and shape of the breasts.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.4
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• pp.29-37
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• 2000

At present there are many theories as to how various lubricants used in forging perform the role of reducing friction. Little work has been carried out to determine the validity of these theories for solid lubricants. This paper covers the development and preliminary results of the experiments devised to illustrate the movement of graphite at the workpiece/tool interface in the work forging temperature range. The paper describes the results obtained from upsetting of rings between two flat dies for measurement of lubricant thickness and compaction of graphite for density-pressure relationship. These allowed the lubricant to be exposed to forging conditions and by applying the principles of Male's ring test the simple generation of a value fur friction factor could also be determined. The experiments have been undertaken to examine the behavior of lubricant for shot blasted surface and change of surface roughness. A simple computer model of the interface has been constructed characterizing the graphite layer in an attempt to simulate the boundary mechanics.

• Journal of Welding and Joining
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• v.22 no.6
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• pp.50-56
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• 2004

MlAB(magnetically impelled arc butt) welding is a sort of pressure welding method by melting two pipe sections with high speed rotating arc and upsetting two pipes in the axial direction. The electro-magnetic force, the driving force of the arc rotation, is generated by interaction of arc current and magnetic field induced from the magnetic flux generator in the welding system. In this study, an openable coil system for the generation of magnetic flux and a 3-dimensional numerical model for analyzing the electro-magnetic field were proposed. Through the fundamental numerical analyses, a magnetic concentrator was adopted for smoothing the magnetic flux density distribution in the circumferential direction. And then a series of numerical analysis were performed for investigating the effect of system parameters on the magnetic flux density distribution in the interested welding area.. Numerical quantitative analyses showed that magnetic flux density distribution generated from the proposed coil system is mainly dependent on the exciting current in the coil and the position of coil or concentrator from the pipe outer surface. And the gap between pipe ends and arc current are also considered as important factors on arc rotating behavior.

• Transactions of Materials Processing
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• v.27 no.3
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• pp.165-170
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• 2018

In order to increase the lifetimes of cold forging dies, insert rings are generally used. In this study, an insert ring and shrunk ring of the flange upsetting die were designed for the cold forging of an automotive wheel nut. The Stress distribution occurring in the die during forging was simulated using a commercial finite element analyzing program. The effects of the fitting interference and inclined angle of the insert ring on the compressive stress of the die inside were also investigated. The simulated data were compared with the real lifetimes of the forging dies. The maximum compressive stress acting on the edge of a forging die should have the most influence on die lifetime, an idea which could help develop the die design with the longest lifetime. The design of the most optimal forging die with the longest lifetime is made possible by analyzing the maximum inner pressure and principal stress between the shrunk ring and insert ring.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.219-222
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• 2005

The temperature difference between die and workpiece has frequently caused various surface defects. The non-homogeneous temperature distribution of forged part should be analyzed to prevent the generation of various defects related with the temperature. The surface temperatures were mainly affected by the coefficient of thermal contact conductance. The precise coefficient is necessary to predict accurately the temperature changes of die and workpiece. The experiment is preformed to measure the temperature distribution of die and workpiece in closed die upsetting. And then, the coefficient is classified into function of pressure and confirmed by the comparison between experiments and FE analyses using the other model. The FE analysis to predict the temperature distribution is performed by commercial software $DEFORM-3D^{TM}$. However, it might be impossible to measure directly the temperature distribution of forged part. Therefore, the comparisons between measured temperature and predicted values are performed with the hardness of Al6061-forged part.

• Journal of Advanced Marine Engineering and Technology
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• v.17 no.4
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• pp.38-48
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• 1993

A study on friction welding of stainless steel bar(SUS431) to chrome molybdenum steel bar(SCM21) was accomplished experimentally through analysis for relations among friction welding conditions, tension test, hardness test, microstructure test and acoustic emission test. The results obtained are summarized as follows ; 1. Through friction welding of SUS431 bar to SCM21 bar, the optimum welding condition by considering on strength and toughness was found to be the range of heating time of 3-5 sec when the number of rotating speed of 2000rpm, heating pressure of 10kg/$mm^2$, and upsetting time of 4 sec. 2. Quantitative ralationship was identified between heating time($T_1$, sec) and tensile strength (${\sigma},\;kgf/mm^2$) of the friction welded joint and the relation equation is $\sigma$=52.62$T_1{^{0.06}}$. 3. Through AE test, quantitative relationship was confirmed between heating time($T_1$, sec) and total AE(N, counts) during welding, and the relation is computed as follows ; N=30413.6$e^{0.06T1}$. 4. It was confirmed that the quantitative ralationship exists between the tensile strength of the welded joints and AE cumulative counts. And the relation is computed as the following ; ${\sigma}$=16.37(ln N)- 116.4. 5. When ONZ=36500-41500 counts by $OT_1Z$=3~5sec, it was identified by experiment that the range of welded joint tensile strength is 55.6-57.7kgf/$mm^2$/ whose joint efficiency is more than 100%, and it was experimentally confirmed that the real-time nondestructive quality(strength) evaluation for the friction welded joints could be possible by acoustic emission technique.

• Journal of Welding and Joining
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• v.7 no.3
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• pp.19-27
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• 1989

Both the SS41 steel and the M.E.F(martensite encapsulated islands of frrite) dual phase steel made of SS41 steel by heat treatment were welded by friction welding, and then manufactured machinemade Vnotch standard Charpy impact specimens and precracked with a fatigue system at BM(base metal), HAZ(heat affected zone) and WZ(weld interface Zone). The impact test of them was performed with an instrumented impact test machine at a number of temperatures in constant loading velocity and the dynamic fracture characteristics were studied on bases of the absorbed energy, dynamic fracture toughness and fractography from the test. The results obtained are as follows; At the room temperature, the absorbed energy is HAZ.geq.WZ.geq.BM in case of the M.E.F. dual phase steel: BM.geq.HAZ.geq.WZ in case of the SS41 steel, HAZ.geq.BM.geq.WZ at the low temperature. The absorbed energy is decreased markedly with the temperature lowering; it is highly dependent on the temperature. The dynamic fracture toughness of the M.E.F. dual phase steel is HAZ.geq.WZ.geq.BM at the room temperature; BM.geq.WZ.geq.HAZ below-60.deg. C. Therefore the reliability of friction welding is uncertain at the low temperature(below-60.deg. C). The dynamic fracture toughness of the SS41 steel; HZA.geq.WZ.geq.BM at overall temperature region. The flaw formed by rotational upsetting pressure was shown y SEM; in this region. The absorbed energy per unit area and dynamic fracture toughness were low relative to other region.

• Journal of the Korean Society of Fisheries and Ocean Technology
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• v.14 no.2
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• pp.79-87
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• 1978

This is an experimental study on friction welding and heat treatment of engine exhaust valve materials whose welding combination is SCr4 as stem to 21-4N as head and SUH3 to 21-4N. In this study, not only the experiments of friction welding under the selected optimum welding condition and the examination of the mechanical properties were carried out, but also the heat treatment of friction welded specimens under the two selected conditions was taken to obtain the better welding character, eliminating the latent stress and the hardness peak which appeared at the welded zones of heat resisting steel(21-4N, SUH3) and low alloyed steel ($SCr_4$) friction weldments. The results obtained by the experiments and consideration in this study are as follows: I) It was experimentally proved quite reasonable that 'speed=3,OOO rpm, heating pressure Pl=8 kg/ mm2, upsetting pressure p, = 20 kg/mm', heating time $t_1$ = 3 see, upsetting time TEX>$t_2$ = 2.5 sec' was selected as the optimum welding condition for friction-welding the engine exhaust valve materials $SCr_4$ to 21-4 Nand SUH 3 to 21-4 N. 2) The results of the previous study and this one on friction welding of such dissimilar materials as SUH 3-SUH 31, SCr 4-SUH 31, SCr 4-SUH 3, SUH 3-CRK 22, SCr4-21-4 Nand SUH3-21-4 N agreed with each other substantially in the friction welding characteristics at welded interface zones. 3) It was also certified quite satisfactory that '600\ulcornerCX30 min. Xroom air cooling' as an optimum heat treatment condition of the friction welded materials SCr 4-21-4 Nand SUH 3-21-4 N was experimentally determined to eliminate the latent stress and the hardness peak at welded zones. 4) About 20% of the tensile strength before heat treatment of friction welded specimens was decreased after heat treatment 600\ulcornerCX30 min. Xair cooling, but the location of fracture was moved from heat affected zone to parent $SCr_4$ & SUH3. 5) Microscopic examination of the weld joints friction-welded and heat-treated under the above mentioned conditions revealed that the weld zone is very narrow and has a fine grained intermixed structure without any welding defects. 6) The above mentioned conditions can be also utilized as friction welding parameters of the other dissimiar materials for engine valve production.