• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.10b
• /
• pp.115-122
• /
• 2003

This paper presents the development of a virtual forging factory framework. The technologies of virtual reality and relational database had been integrated in the developed framework using Microsoft $Windows^{(R)}$ programming as the main technique so as to emulate a physical forging factory. The developed virtual forging factory consists of forging cells and a forging cell is comprised of forging machine, forging die, and forging operations forming a forging production line. The technology of virtual reality had been successfully adopted in the production simulation of manufacturing such as CNC and robotics. However, the application in virtual forging factory seems to have not been studied yet. Potential application of a virtual forging factory can be beneficial to (1) computer aided instruction, (2) shorten the learning curve of a novice, (3) remote diagnosis and monitoring when remote monitoring and control technology and signal inspection is considered, (4) improve adverse forging environment when remote forging technology is applied, and (5) virtual reality application.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.05a
• /
• pp.225-229
• /
• 2008

We present an intelligent forging simulator AFDEX. The intelligent forging simulator is determined by the adaptive and optimal mesh generation technique and many intelligent application-oriented special functions which minimize the user-intervention during forging simulation. Of course, the solution accuracy should be optimized in the intelligent simulation. We have developed AFDEX to meet the requirement on intelligent simulation. Its characteristics are introduced with the help of typical application examples.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2007.10a
• /
• pp.75-77
• /
• 2007

Mg alloys have the highest specific strength which can be used industrial application. Since formability of Mg alloys is very limited, optimization of forming process is always needed for successful engineering application. In the present study. three different Mg alloys were used for hot forging processes and several process variables such as temperature and forging speed were investigated to improve forgeability of Mg alloys. To understand the effect of process variables in details, 2D-finite element analysis and forging experiment was performed. In the results, forging speed seems to be more important than forging temperature in hot forging of Mg alloys.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.10b
• /
• pp.133-137
• /
• 2003

In this paper presented the net forging technology of planetary gear after much experiment and analysis, technology of two forging processes after billet being one -time heated, and cold net forging was adopted to ensure the gear forming quality. In the process of die producing, electrical rod NC cutting technology was used .the test and application has proved the net forging gear has reached higher quality and met the requirement of design. The net forging gear technology had been put into production.

• Journal of the Korean Society for Precision Engineering
• /
• v.19 no.12
• /
• pp.158-162
• /
• 2002

In this paper, the usefulness of a three-dimensional forging simulation technique is verified through its application to process design in rotor pole forging. A simulator, AFDEX3D developed based on the rigid-plastic finite element method and hexahedral elements, is employed. The simulated results of an application example found in a precision forging company are compared with the actually forged ones in detail. It has been verified that the simulation results are in good agreement with the actual phenomena.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2005.10a
• /
• pp.143-147
• /
• 2005

In this study, a die set for enclosed die forging is developed and it is applied to precision forging of bevel gears and spiders. The enclosed die forging die set is introduced in detail together with the enclosed die forging. A target mechanical press and a model product are selected and various engineering technologies are applied for detail design of the enclosed die forging die set. Several precision forgings are manufactured by the developed die set. The enclosed die forging die set as well as the precision forging processes are developed under intensive industry-university cooperation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.05a
• /
• pp.263-266
• /
• 2008

We apply a closed die forging technology to a large crankshaft of which forging weight amounts to 850kg. 40ton counter-blow hammer forging machine is used. The forging process is optimized to reduce the forming load using finite element simulation. AFDEX 3D is used for forging simulation. The experiment is compared with finite element prediction and a good agreement is observed. The successful development of a large crankshaft by the closed die forging technology will contribute to opening a new area of closed-die forging application and to enhancing competitiveness of national machinery industries especially including ship part and power generation industries.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 1999.03b
• /
• pp.86-89
• /
• 1999

Structural analysis of die set in cold forging is conducted by the finite element method and the results are introduced in this paper. The problem formulation is introduced in detail. In the approach, amount of shrink fit is controlled by thermal load, i.e., temperature difference between die insert and shrink fits. The loading conditions are extracted automatically from a forging simulator. An application example is given.

• Transactions of Materials Processing
• /
• v.8 no.4
• /
• pp.384-392
• /
• 1999

In metal forming, there are problems with recurrent geometric characteristics without explicitly prescibed boundary conditions. In such problems, so-called recurrent boundary conditions must be introduced. In this paper, as a practical application of the proposed method, the precision cold forging of a helical gear has been simulated by a three-dimensional rigid-plastic finite element method and compared with the experiment. The application of recurrent boundary conditions to helical gear forging analysis is proved to be effective and valid. the elastic stress analysis of the die for helical gear forging has been calculated by using the nodal force at the final stage obtained from the rigid-plastic finite element analysis. In order to obtain more precise gear products, the elastic analysis of the die after release of punch and the elastic spring-back analysis of product after ejection have been performed, and the final dimension of the computational product has been in good agreement with that of the experimental product.

• Transactions of Materials Processing
• /
• v.30 no.4
• /
• pp.172-178
• /
• 2021

The cold forging process induces material deformation in an enclosed space, generating a very high forging load. Therefore, it is mainly designed as a multi-stage process, and fatigue failure occurs in forging die due to cyclic load. Studies have been conducted previously to quantitatively predict the fatigue limit of cold forging dies, however, there was a limit to field application due to the large error range and the need for expert intervention. To solve this problem, we conducted a study on the introduction of a real-time forging load measurement technology and an automated system for quantitative prediction of die life cycle. As a result, it was possible to reduce the error range of the quantitative prediction of die life cycle to within ±7%, and it became possible to use the die life cycle calculation algorithm into an automated system.