• Transactions of the Korean Society of Mechanical Engineers
• /
• v.19 no.4
• /
• pp.896-907
• /
• 1995

Titanium 6242(.alpha. + .betha.) alloy has a good strength/weight ratio and is used for aircraft components such as engine disks and compressor blades. When this material is forged at an elevated temperature, the process parameters should be carefully controlled because the process window of this material is quite narrow. In the present investigation, a rigid-thermoviscoplastic finite element method is used to predict the deformation behavior and temperature/strain distributions in an engine disk during near-net shape hot forging. The purpose of the investigation is to obtain a proper ram speed profile, assuming the hydraulic press used in the forging is capable of varying ram speed during loading. In result, it was found that the ram speed at constant strain-rate of 0.5/sec shows a sound deformation behavior, a relatively uniform deformation and a good temperature distribution. This information is also valuable in predicting resulting microstructures in the disk.

• Transactions of Materials Processing
• /
• v.12 no.4
• /
• pp.408-413
• /
• 2003

Dies may have to be replaced for a number of reasons, such as changes in dimensions due to die wear or plastic deformation, deterioration of the surface finish, break down of lubrication and cracking or breakage. In this paper, die cooling methods have been suggested to improve die service life considering die wear and plastic deformation in hot forging process. The yield strength of die decreases at higher temperatures and is dependent on hardness. Also, to evaluate die life due to wear, modified Archard's wear model has been proposed by considering the thermal softening of die expressed in terms of the main tempering curve. It was found that the use of die with cooling hole was more effective than that of direct cooling method to increase the die service life for spindle component.

• Transactions of Materials Processing
• /
• v.14 no.9 s.81
• /
• pp.791-797
• /
• 2005

Extensive width reduction of slabs is an important technology for achieving continuous production between the steelmaking and hot rolling processes. However, the vertical horizontal rolling process has many disadvantages, e.g., large width deviations and less efficient width reduction. This study was carried out to investigate the deformation of slab by sizing press with two steps die. To do it, dog-bone and camber are discussed in width sizing process considering the deformation behavior according to the deviation of anvil velocity and the deviation of initial slab temperature. In this paper, the various causes of the sizing press phenomena are mentioned for the purpose of understanding of rolling conditions. As a result, the optimal anvil shape having a minimum-forming load is obtained by FE-simulation and ANN.

• Transactions of Materials Processing
• /
• v.25 no.1
• /
• pp.56-60
• /
• 2016

Precise prediction and control of the strip profile is crucial for automatic process set-up and operation of a hot strip mill. In the current study, we present the effect of post-deformation on the steady-state strip profile. The process was simulated by a 3-D elastic-plastic finite element (FE) analysis. Comparisons are made between the strip profile measured at the roll exit and the steady-state strip profile. The results raised an issue with regard to the importance of taking into account the effect of post-deformation.

• International Journal of Precision Engineering and Manufacturing
• /
• v.6 no.4
• /
• pp.55-59
• /
• 2005

This paper presents a feasibility study whether Shida's constitutive equation being widely used for plain carbon steel in steel manufacturing industry can be extended to alloy steels with a due carbon equivalent model. T,he constitutive relation of the alloy steels (SAE9254, AISI52100 and AISI4140) is measured using hot deformation simulator (GLEEBLE 3500C) at high temperatures ($800^{\circ}C{\~}1000^{\circ}C$) within strain rates of $0.05{\~}40\;s^{-1}$. It has been found the predicted flow stress behavior (constitutive relation) of AISI52100 steel is in agreement with the measured one. On the other hand, the measured flow stress behavior of SAE9254 and AISI4140 steel partly concords with the predicted one when material experiences relatively high strain rate ($10{\~}40\;s^{-1}$) deformation at low temperature ($800^{\circ}C$). It can be deduced that, for AISI52100 steel, Shida's equation with the carbon equivalent model can be applicable directly to the roughing and intermediate finishing stand in hot rolling process for calculating the roll force and torque.

• Journal of the Korean Society for Precision Engineering
• /
• v.20 no.7
• /
• pp.26-35
• /
• 2003

This study explains the effects of lubricant and surface treatment on hot forging die life. The mechanical and thermal load, and thermal softening which is happened by the high temperature of die, in hot and warm forging, cause die wear, heat checking and plastic deformation, etc. This study is fur the effects of solid lubricants and surface treatment condition for hot forging die. Because cooling effect and low friction are essential to the long life of dies, optimal surface treatment and lubricant are very important to improve die life for hot forging process. The main factors, which affect die hardness and heat transfer, are surface treatments and lubricants, which are related to thermal diffusion coefficient and heat transfer coefficient, etc. For verifying these effects, experiments are performed for hot ring compression test and heat transfer coefficient in various conditions as like different initial billet temperatures and different loads. The effects of lubricant and surface treatment for hot forging die life are explained by their thermal characteristics. The new developed technique in this study for predicting tool life can give more feasible means to improve the tool life in hot forging process.

• Transactions of the Korean Society of Automotive Engineers
• /
• v.15 no.1
• /
• pp.154-161
• /
• 2007

Hot spot phenomenon that occurs, during judder vibration, is locally concentrated heat due to friction between brake disk and pad. It is important to understand the reason behind hot spot phenomenon, for reduction of judder vibration. In this experimental study, experiments were performed in accordance with rotation speed of brake disk, pressure of master cylinder and pad length for achieving different aspects of hot spot phenomenon. Temperature distribution of hot spot was obtained by using the infrared camera. As the hot spot occurred, vibration was measured and frequency analysis was performed. Finite element analysis of thermal deformation of disk was performed by using temperature distribution that was achieved by experimental results. And mode shapes of disk was analyzed by finite element analysis and compared with experimental results. It was observed that the excitation frequency band of frictional contact and frictional force mainly affects the hot spot phenomenon.

• Journal of the Korean Society for Precision Engineering
• /
• v.16 no.6
• /
• pp.183-189
• /
• 1999

A numerical analysis was performed to predict flow curves and dynamic recrystallization behaviors of Al-5wt%Mg alloy on the basis of results of hot compression tests. The hot compression tests were carred out in the ranges of 350 ~ 500 ${^\circ}C$ and 5 ${\times}{10^-3}$ ~ 3 ${\times}{10^0}$/sec to obtain the Zener-Hollomon parameter Z. The modelling equation for flow stress was a function of strain, strain rate, temperature. The influence of these variables was quantifield using the Zener-Hollomon parameter. In the modelling equation, the effects of strain hardening and dynamic recrystallization were taken into consideration. Therefore, the modelling stress-strain curves of Al-5wt%Mg alloy were in good agreement with experimental results. Finally, the dynamic recrystallization kinetics were illustrated through the inspection of microstructure after deformation.

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.14 no.5
• /
• pp.1166-1180
• /
• 1990

The study is concerned with the two-dimensional thermo-viscoplastic finite element analysis for radial forging as an incremental forging process. The deformation and temperature distribution of the workpiece during radial forging are studied. The analysis of deformation and the analysis of heat transfer are carried out for simple upsetting of cylinder by decoupling the above two analyses. A method of treatment for heat transfer through the contact region between the die and the workpiece is suggested, in which remeshing of the die elements is not necessary. Radial forging of a mild steel cylinder at the elevated temperature is subjected to the decoupled finite element analysis as well as to the experiment. The computed results in deformation, load and temperature distribution are found to be in good agreement with the experimental observations. As an example of viscoplastic decoupled analysis of hot radial forging, forging of a square section into a circular section is treated. The stresses, strains, strain rates and temperature distribution are computed by superposing material properties as the workpiece is rotated and forged incrementally. It was been thus shown that proposed method of analysis can be effectively applied to the hot radial forging processes.

• Transactions of Materials Processing
• /
• v.9 no.1
• /
• pp.72-79
• /
• 2000

Dynamic recrystallization (DRX), which may occur during hot deformation, is important for the microsturctural evolution of 304 stainless steel. Especially, the current interest in modelling hot rolling demands quantitative relationships among the thermomechanical process variables, such as strain, temperature, strain rate, and etc. Thus, this paper individually presents the relationships for flow stress and volume fraction of DRX as a function of processing variables using torsion tests. The hot torsion tests of 304 stainless steel were performed at the temperature range of 900~110$0^{\circ}C$ and the strain rate range of 5x10-2~5s-1 to study the high temperature softening behavior. For the exact prediction of flow stress, the equation was divided into two regions, the work hardening (WH) and dynamic recovery (DRV) region and the DRX region. Especially, The flow stress of DRX region could be expressed by using the volume fraction of DRX (XDRX). Since XDRX was consisted of the critical strain($\varepsilon$c) for initiation of dynamic recrystallization (DRX) and the strain for maximum softening rate ($\varepsilon$*), that were related with the evolution of microstructure. The calculated results predicted the flow stress and the microstructure of the alloy at any deformation conditions well.