• Proceedings of the KIEE Conference
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• 1998.11a
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• pp.34-36
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• 1998

Induction heating is utilized in a large and ever-increasing number of application. The most prominent of these are billet heating, heat treating, metals joining, and metal melting. In these day, heating roll, a kind of induction heating, is widely used in curing of coatings and fiber industry. We designed and manufactured heating roll that in order to distribute uniform temperature on the roll's surface. Then Heating roll's characteristic analysis was studied and performed the test of temperature distribution.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.266-269
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• 2005

The effect of exit temperature on the thickness of recrystallization layer during Al extrusion process was investigated. The recrystallization layer of an extruded Al alloy is an important feature of the product in a wide range of applications, particularly those within the automotive industry. The thicker recrystallized layer in the Al alloys can give rise to a number of problems including reduced fatigue resistance and orange peel during cold forming. But the interaction of extrusion process variables with the thickness of recrystallization layer is poorly understood, and there is limited information available regarding the role of the main hot extrusion variables. Using the 3650 US ton extrusion press, this paper describes the effect of the main process variables such as billet temperature, ram speed, and exit temperature on the thickness of recrystallization layer for the A6XXX Al alloy.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.450-453
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• 2008

During the drawing of reentrant section like a spline, the unfilled in the corner of dies or the bended product emerges from the large reduction of area, the complex shaped sections and other nonuniform properties in material and lubrication conditions. In this study, the drawing of the spline section with the non-rotary symmetry from a circular aluminum billet has been analyzed by using commercial code DEFORM-3D. A new die construction method preventing the spline from the drawback of bending and the unfilled defect has been suggested and verified through the analysis using centroid shift method and the hybrid construction between converged and diverged profile.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.7
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• pp.119-128
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• 1998

In this paper, nonsteady state shaped drawing process has been investigated using the three-dimensional rigid-plastic finite element method. In order to analyze the shaped drawing process, a method to define straight converging die considering straight die part, die radius part and bearing part has been proposed. In addition, the modeling of initial billet and the generation procedure of mesh system have been suggested. The three-dimensional rigid-plastic finite element simulation has been performed for a square sectional drawing process and its result has been confirmed in comparison with the existing experimental one. Also, for the same process conditions, the effect of perimeter ratio in the shaped drawing process has been investigated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.993-996
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• 2005

This paper is concerned with transfer process on hot forging of bearing hub. Workers on hot forging have difficulty in working by high temperature and weight workpiece. And In conventional got forging of bearing hub, the material wasted to the flash accounts approximately 10% of the original workpiece. It is need manufacture automation and reduce the cost of forged products. Surface treatment of die and lubricant are investigated from experiment and FE-simulation for analysis of forming simulation. In order to hot forging process design considered flash thickness and blocker geometry and initial temperature of die and billet. This transfer process gave comparatively good results compared with actual products.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.8
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• pp.92-100
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• 1997

An upper-bound elemental technique (UBET) analysis is carried out to improve the material flow and to reduce the load of bearing-race forming process. The UBET analysis, which adapts the advantages of stream function and finite element method, is useful for predicting the profile of complex geometric bound- ary. From the UBET analysis, the forming load, the velocity distribution and the stream line of the deformed billet are determined by minimizing the total power consumption with respect to chosen parameters. The results of present UBET analysis are better than those of previous UBET analysis. Experiments have been carried out with model material plasticine billets at room temperature. The theoretical predictions for forming load and flow pattern(stream line) are in good agreement with the experimental results.

• Journal of Korea Foundry Society
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• v.39 no.2
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• pp.26-31
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• 2019

In this study, the mechanical characteristics and microstructure of hypereutectic Al-17Si-5Fe extruded alloys prepared by a rapid solidification process (RSP) were investigated. The hypereutectic Al alloy was fabricated by means of RSP and permanent casting. For RSP, the Al alloy melted at $920^{\circ}C$, cooling the specimens at a rate of $10^6^{\circ}C/s$ when the RSP was used, thus allowing the refining of primary Si particles more than when using permanent casting, at a rate of about 91%. We tested an extrusion RSP billet and a permanent-cast billet. Before the hot-extrusion process, heating to $450^{\circ}C$ took place for one hour. The samples were then hotextruded with a condition of extrusion ratio of 27 and a ram speed of 0.5 mm/s. Microstructural analyses of the extruded RSP method and the permanent casting method were carried out with OM and SEM-EDS mapping. The mechanical properties in both cases were evaluated by Vickers micro-hardness, wear resistance and tensile tests. It was found that when hypereutectic Al-17Si-5Fe alloys were fabricated by a rapid solidification method, it becomes possible to refine Si and intermetallic compounds. During the preparation of the hypereutectic Al-17Si-5Fe alloy by the rapid solidification method, the pressure of the melting crucible was low, and at faster drum speeds, smaller grain alloy flakes could be produced. Hot extrusion of the hypereutectic Al-17Si-5Fe alloy during the rapid solidification method required higher pressure levels than hot extrusion of the permanent mold-casted alloy. However, it was possible to produce an extruded material with a better surface than that of the hot extruded material processed by permanent mold casting.

• Journal of Korea Foundry Society
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• v.41 no.3
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• pp.241-251
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• 2021

7000-series aluminum alloys are noted for their superior strength compared with other Al alloys, and their billets are generally fabricated by direct-chill (DC) casting. Surface defects in a DC-cast aluminum billet are mainly related to exudation and the meniscus freezing phenomenon, which are influenced by alloy compositions, casting speed, and casting temperature. 7000-series aluminum alloys have a wide freezing range during solidification, which makes it easy for casting defects to occur. In this study, we investigated surface defect evolution in casting billets of Al-8Zn-2Mg-2Cu alloy fabricated by a DC casting process. The billets showed "wavy" or "dotted" surfaces. The wavy surface was formed by meniscus freezing at a lower casting speed (200 mm/min) and temperature (655 ℃). In the wavy surface, refined dendritic cells were observed in a concave region due to the constitutional supercooling caused by meniscus freezing. Meanwhile, at a higher casting temperature (675 ℃), the dotted surface was formed by pore formation. In the dotted surfaces in the billet formed at a high casting speed (230 mm/min), an exudation layer was formed by the high metallostatic head pressure. The dotted region and the smooth region had a refined dendritic morphology and a columnar morphology at the exudation layer, respectively. This is attributed to the formation of gas pores in the dotted region.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.417-420
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• 2007

Micro parts are usually used of producing by micro-electro-mechanical systems(MEMS). In this paper, we present some fundamental results concerning on the MEMS, extrusion condition on the micro forming characteristics and new micro forward extrusion machine has been developed. In the first step, we manufactured micro dies in two kinds of sections. One is a circle section, another is a cross section. The process for fabricating micro dies combines a deep UV-lithography, anisotropic etching techniques and metal electroplating with bulk silicon based on Ni with a thickness of $50{\mu}m$. The outer diameter of Ni-micro dies is 3mm and the diameter of extrusion section is $270{\mu}m$ for a cross section, $500{\mu}m$ for a circle section. The low linear density polyethylene(LLEPD) in the shape of a pellet has been used of micro extrusion. The billet was placed in a container manufactured by electric discharge machining and extruded through the micro die by a piezoelectric actuator. The micro extrusion has succeeded in a forming such micro parts as micro bars, micro cross shafts.

• Journal of Korea Foundry Society
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• v.20 no.5
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• pp.290-299
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• 2000

A three-dimensional model was developed in order to simulate heat and fluid flow of a continuous casting billet. The model was coded with the general-purpose CFD program FIDAP, using the finite element method. The present model consists of 2 individual calculation schemes, named model 1 and model 2. Mold region only was calculated to check the pouring stream through submerged nozzle with model 1. Entire region, which consists of mold, secondary cooling, radiation cooling was calculated to predict crater end position, temperature profile and solid shell profile(model 2). Standard $k-{\bullet}\hat{A}$ turbulence model has been applied to simulate the turbulent flow induced by submerged nozzle. Enthalpy method was adopted for the latent heat of solidification. Fluid flow in mushy zone was treated using variable viscosity approach. The more casting speed and superheat increased, the more metallurgical length increased. The shell thickness at the mold exit is proved to be mainly controlled by superheat by the present simulation. It may be concluded that the present model can be successfully applied far the prediction of heat and fluid flow behavior in the continuous casting process.