• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.75-78
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• 2008

The predictive equation of void-closure was developed to evaluate void crush ratio with respect to the process variables in the cogging process of a large round bar. The comprehensive finite element analysis with the process variables such as reduction ratio and die width ratio was carried out. The predictive equation of void-closure for cogging process was established on the basis of the regression analysis with the extensive FE analysis results and verified by comparing the predicted results with FEA results with various forging passes.

• 소성∙가공
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• 제20권5호
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• pp.339-343
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• 2011

This paper presents methods for analyzing the extent of cylindrical-shaped void closure. In addition, a quantitative relationship between change in void fraction and height reduction ratio of a compressed specimen is proposed. The height reduction ratio, number of deformation steps and billet rotation were chosen as key process parameters influencing the void closing behavior, namely, the changes in void shape and size during hot open die forging of a large ingot. The extent of void closure was analyzed from microscopic observations and estimated from tensile test results. The tensile strengths of specimens with closed voids and those without were compared for various reduction ratios in height. The results confirmed that void closure occurs at reduction ratios greater than 30 %. The void closing behavior could be expressed as a hyperbolic tangent function of reduction ratio in height, number of paths, and billet rotation. The knowledge presented in this paper could be helpful for optimizing deformation paths in open die forging processes.

• 소성∙가공
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• 제13권2호
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• pp.148-153
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• 2004

Finite element analysis of open die forging process to make rectangular billet has been performed in this study. Three dimensional rigid-plastic finite element method was used to analyze the effects of process variables, forging pass design and die configurations on the void closure phenomena to maximize the internal deformation for better structural homogeneity and center-line consolidation of the rectangular billet. The effect of anvil width ratio, anvil pitch, anvil shape and number of pass has been estimated by the degree of void closure ratio. Although it is difficult to optimize process parameters in the operational environments, favourable process conditions are suggested for better product quality.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 추계학술대회 논문집
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• pp.406-409
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• 2005

In the forging operation of large ingot two break-down process are upsetting and cogging. The first purpose of upsetting is to ensure sufficient forging ratio for subsequent cogging operations and consolidate the voids along the centerline. The second purpose is related to improve the physical properties for a final product. Voids which are generated during the casting process can be one of the decisive defects of materials. So it is necessary to know the standard of Judgment for void-closure in upsetting operation. In practical conditions, FEM analysis(DEFORM 2D 8.1) was carried out to decide how much effective strain has influence on void-closure. It is finally suggested that the function consists of the effective strain of analysis data and the area rate of void.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2009년도 춘계학술대회 논문집
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• pp.114-117
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• 2009

In this work, closing behavior of the voids generated in a casting process was investigated for various parameters such as reductions in height void size and billet rotation during hot open die forging process. The reduction in height and path schedule including the number of paths and billet rotation were chosen as key process variables to express the change of geometrical void shape and void closing behavior. On the other hand, values of die overlapping and die width ratio were set to be constant. Extend of void closure was observed and evaluated using tensile test and microscope. Based on the experimental result, it is ensured that void closure do not occur at 15% and 30% reduction in height as well as one or two rotations of a billet. The useful datum obtained from this study could be utilized to establish an optimum path schedule in the open die forging process.

• 소성∙가공
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• 제22권5호
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• pp.269-274
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• 2013

Experiments and numerical simulations of the incremental upsetting test were carried out to investigate void closure behavior and mechanical characteristic of a 1.5wt%C ultra-high carbon steel. The experimental results showed that the voids become quickly smaller as the reduction ratio increases. The simulation results confirmed this behavior and indicated that the voids were completely closed at a reduction ratio of about 40~45% during incremental upsetting. After the completion of the incremental upsetting tests, the process of diffusion bonding was employed to heal the closed voids in the deformed specimens. To check the appropriate temperature for diffusion bonding, deformed specimens were kept at 800, 900, 1000 and $1100^{\circ}C$ for an hour. In order to investigate the effect of holding time for diffusion bonding at $1100^{\circ}C$, specimens were kept at 10, 20, 30, 40, 50 and 60minutes in the furnace. A distinction between closed and healed voids was clearly established using microstructural observations. In addition, subsequent tensile tests demonstrated that complete healing of a closed void was achieved for diffusion bonding temperatures in the range $900{\sim}1100^{\circ}C$ with a holding time larger than 1 hour.

• 대한기계학회논문집
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• 제16권10호
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• pp.1877-1889
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• 1992

본 연구에서는 업셋팅의 변형해석 및 온도해석(열전달 해석)을 비연계 방식으 로 동시에 해석하고 실제 공정에 가깝게 접근하는 축대칭 열점소성 유한요소 프로그램 을 이용하여, 시뮬레이션에 의해 공정을 해석하여 불량감소 및 원가절감을 위해 단조 공정을 개선하는 것이다. 업셋팅공정의 연구에 있어서는 대형강괴의 주 불량요인인 기공의 소멸을 위한 공정방안을 연구하는데 있다.

• 소성∙가공
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• 제22권8호
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• pp.463-469
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• 2013

In the previous work, a new forging process design, which included incremental upsetting, diffusion bonding and cogging, was suggested as a method to manufacture 1.9wt%C ultrahigh carbon workrolls. The previous study showed that incremental upsetting and diffusion bonding are effective in closing voids and healing of the closed void. In addition, compression tests of the 1.9wt%C ultrahigh carbon steel revealed that new microvoids form within the blocky cementite at temperatures of less than $900^{\circ}C$ and that local melting can occur at temperatures over $1120^{\circ}C$. Thus, the forging temperature should be controlled between 900 and $1120^{\circ}C$. Based on these results, incremental upsetting and diffusion bonding were used to check whether they are effective in closing and healing voids in a 1.9wt%C ultrahigh carbon steel. The incremental upsetting and diffusion bonding were performed using sub-sized specimens of 1.9wt%C ultrahigh carbon steel. The specimen was deformed only in the radial direction during the incremental upsetting until the reduction ratio reached about 45~50%. After deformation the specimens were kept at $1100^{\circ}C$ for the 1 hour in order to obtain a high bonding strength for the closed void. Finally, microstructural observations and tensile tests were conducted to investigate void closure behavior and bonding strength.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2008년도 춘계학술대회 논문집
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• pp.71-74
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• 2008

In order to resolve the problems which appear after the clean large ingot production process, the impurities which are involved in the steel smelting process should be removed by developing cleaner materials. Through the rationalization of cogging process that is the first forging process of large ingot the quality is to be improved. For the sake of the optimization of an open die forging process and the improvement of the subject matter frequency ratio, a hazard precise die forging process must be developed and a Near Net Shape Forming accomplished. As a result, energy can be reduced by minimizing an after control process. In order to produce large axes and other forming parts, processing techniques are to be developed. In this context, this paper is a study about a reduction ratio, dies width ratio and rotary angles, the amount of overlap, and intends to analysis cogging processes, utilizing Deform-3D cogging module