• 소성∙가공
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• 제8권5호
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• pp.437-448
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• 1999

The reheating of the billet in the semi-solid state as quickly and homogeneously as possible is one of the most imposrtant parts. To obtain a fine globular microstructure in cross section of billet, the optimal design of the induction coil for variation of alloys and specimen sizes is necessary. For the thixo-forging process the construction of the reheating data base is very important, because the reheating conditions are different for variation of SSM and billet sizes. So in this study, the optimal coil design of A356 (ALTHIX) and Aι2024 with d×ι=60×90 (mm) to obtain the globular microstructure is theoretically proposed. The suitability of an optimal coil design will be demonstrated by reheating experiments. Finally, the thixoformability of an arbitrarily shaped product is evaluated by its forming variables. The defects and mechanical properties are also investigated.

• 소성∙가공
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• 제6권4호
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• pp.329-337
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• 1997

Forging of an inner pulley for compressor clutch assembly of car air conditioner is investigated in this study. In cold forging of inner pulley, the design requirements are to keep the same height of the inner rib and the outer one, and to make uniform the hardness distribution in the forged product. Using the rigid-plastic finite element simulation. we design the optimal process conditions, which has a performing operation. Also the final product configuration of forging has to be designed again in view of the metal flow involved in the operation, derived from the finite element simulations. The forged pulley is investigated by checking the hardness distribution and it is noted that the distribution has improved to be even and high enough for industrial application.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2009년도 춘계학술대회 논문집
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• pp.365-367
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• 2009

The use of aluminum alloy has been interested in the automotive industry, because of its specific strength. And hollow extruded billet is more attractive than solid extruded billet but its forming application has to be precisely processed to satisfy the product quality. In this research, the process design of forming of control arm for the vehicle was studied by press bending process with hollow extruded billet. The middle protrusion portions and the middle cylindrical cup were processed separately according to the analysis. It was concluded that a useful sequence is to bend the side flange and the middle protrusion portions firstly, and then to form the middle cylindrical cup.

• 소성∙가공
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• 제5권2호
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• pp.115-121
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• 1996

Recently it is attempted to manufacture gears by various cold forging methods to meet requirements of mass production and uniform qualities. Compared to machined gears cold forged ears reveal higher tooth strength and better surface roughness but they reveal lower geometrical accuracies. Therefore in the present study a series of experiments are performed to investigate relations between geometrical accuracies of dies and billet and those of the final product. The geometrical accuracies of forged gears are considered through functional gear-element tolerances by measuring pitch error profile error lead error radial error tooth thickness and rolling test. Results of the experiments can be summarized as follows: (1) involute spur gears of KS 5(or AGMA7) accuracies can be made,(2) concentricity of die set should be maintained within 0.01mm (3) clearance between the billet and die set should be less than 0.1mm (4) con-centricity and radial runout should be less than 0.08mm and 0.1mm respectively. However it is thought that FEM analysis of elastic/thermal deformations of dies and the billet is necessary for a better understanding of the findings obtained through the present study.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1995년도 추계학술대회 논문집
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• pp.113-116
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• 1995

In this experimental study,aluminum hotforging was conduct to get superior pistion to cast piston. Cast structure of billet is destroyed, harmful defects is removed by forging process. We proposed the direction od die design by observing formability of product according to die shape. The microstructure of forged products with different preform was investigated to determine inital billet shape. We proposed appropriate heat treatment condition for improvement of mechanical properties.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1997년도 추계학술대회논문집
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• pp.138-141
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• 1997

CFM(Cast Forge Method) is widely used in manufacturing industry to produce aluminium parts with good mechanical properties and low production cost. CFM is the process which produces a final products by forging from the initial billet by casting. The study on this paper covers the automatic design method which finds a pertinent shape for initial billet using Fast Fourier Transform, low-pass frequency filtering and FEM simulation of the nonisothermal forging process by DEFORM. These works will give us an information to enhance the low strength of a aluminium casting.

• 동력기계공학회지
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• 제20권6호
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• pp.40-45
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• 2016

The manufacturing process of large scaled Al 7050 alloy is difficult for the occurrence of solidification crack during casting. The aims of this study are the evaluations of microstructure and mechanical properties of extruded Al 7050 billet and ring forged one with large scale. Large scaled Al 7050 billet was casted by direct-chill casting process. The extruded and ring forged specimens were prepared from the casted ingot after residual stress relief and homogenization heat treatment, respectively. Microstructures, hardness and tensile test of the surface, middle and center part of each specimen were performed at room temperature. Sheared and elongated type grains were observed at the edge parts of surface and center area and its aspect ratios of grains were low and similar as 0.21 while that of middle area was closed to 0.92 value in ring forged Al 7050 alloy. The mechanical properties of extruded Al 7050 alloy were superior than those of ring forged one. The hardness values of surface and center part were slightly higher than that of middle part in ring forged Al 7050 alloy.

• 한국주조공학회지
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• 제43권6호
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• pp.286-293
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• 2023

본 연구에서는 고강도 Al-Mg-Zn계 알루미늄 합금 연속주조 빌렛의 균질화처리 과정 중 미세조직 전개과정을 다양한 장비(OM, SEM, EDS, DSC)로 분석 및 고찰하였다. 우선, 연속주조된 알루미늄 합금 빌렛 내 입계 및 입내에는 AlMgZn, AlMgFe 및 AlMgZnSi상 등 많은 양이 불균일하게 존재하며, 이들 상은 균질화처리 과정 중 입계 및 기지로 용해된다. 합금설계 프로그램 및 동력학 방정식을 활용한 결정립 내 주요 합금원소인 Mg 및 Zn의 확산거동을 분석한 결과, JMatPro 내 균질화처리 모드에서 대상합금 내 Mg이 Zn 대비 기지 내로 빠르게 용해되나, 동력학 방정식의 경우에도 유사한 경향성이 나타난다. 확산속도에 대한 의미로 실제로 Zn 대비 상대적으로 Mg이 많은 양을 함유하고 있어 기지로 확산과 동시에 고용되었음을 확인할 수 있었다.

• 소성∙가공
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• 제18권2호
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• pp.150-155
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• 2009

A shaft for laser printers has to be produced with high dimensional accuracy of a few micrometers. Most companies produce the shaft, therefore, by machining. These days, forging process is tried to be employed in manufacturing the shaft for productivity. In this study, the dimensional inaccuracy of straightness is studied and the underfill is not focused because the shaft shape is simple and the load capacity of press is sufficient. The straightness and concentricity of the shaft is important for the operation of a laser printer. Many design parameters such as preform shapes, tooling dimensions, forging load, and billet geometries may affect on the dimensional accuracy. In the forging process of shafts, a billet which is cut from wires is used. The billet, therefore, may be a little bit curved but not always straight. The elastic recovery is considered to cause the dimensional inaccuracy. Therefore, the effect of the forging load on the elastic recovery and straightness is investigated through the finite element analyses using DEFORM-3D and ABAQUS.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2003년도 춘계학술대회논문집
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• pp.210-215
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• 2003

A terminal pin, which is a part of high-voltage capacitors, has a head section of plate-shaped geometry with 0.8 thickness. The current manufacturing process, in which the head section is welded on the body part, has given wide deviations of part qualities such as geometrical accuracy, mechanical strength and electrical stability. In this paper, a cold forging process sequence was designed in order to produce the terminal pin as one piece. The plate-shaped head section requires an upsetting in the lateral direction of a cylindrical billet, which is followed by a blanking process. The deformed geometry of the upsetting, however, could not be predicted precisely by intuition since metal flows of an axial and a lateral direction of the cylindrical billet would occur simultaneously. Therefore, the geometry of the initial billet was determined by three dimensional finite element analysis in order to avoid defects in blanking process and intermediate forging processes were designed by applying design rules and two dimensional FE analysis. In addition, cold forging tryouts were conducted by using the die sets which were manufactured based on the designed process sequence.