• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.198-203
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• 1995

In the paper, we have proposed a new technique to detemine the initial billet for the forged products using a function approximation in neural network. A three-layer neural network is used and a back propagation algorithm is employed totrain the network. An optimal billet which satisfied the forming limitation, minimum of incomplete filling in the die cavity, load and energyas well as more uniform distribution of effective strain, is determined by applying the ability of function approximation of te neural network. The amount of incomplete filling in the die, load and forming energyas well as effective strain are measured by the rigid-plastic finite element method. The new technique is applied tofind the optimal billet size for the axisymmetric rib-web product in hot forging. This would reduce the number of finite element simulation for determing the optimal billet of forging products, further it is usefully adapted to physical modeling for the forging design.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.04a
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• pp.546-550
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• 1996

A fully automatic computer simulation technique of axisymmetric multi-stage compound forging processes was presented in this paper. A penalty rigid-viscoplastic finite element method was employed together with an improved looping method for automatically remeshing with quadrilateral finite-elements only. An application example of six-stage axisymmetric forging processes involving one cold and two hot forging processes, two piercing processes and a sizing process was given with emphasis on automatically tracing the metal flow lines through the whole simulation.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.12
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• pp.1093-1100
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• 2014

The goal of this paper is to investigate preliminary the applicability of 3D printing technologies for the development of the hot bulk forming process and die. 3D printing technology based on the plastic material was applied to the preform design of the hot forging process. Plastic hot forging dies were fabricated by Polyjet process for the physical simulation of the workpiece deformation. The feasibility of application of Laser-aided Direct Metal Rapid Tooling (DMT) process to the fabrication of the hot bulk metal forming die was investigated. The SKD61 hot-working tool steel was deposited on the heat treated SKD61 using the DMT process. Fundamental characteristics of SKD 61 hot-working tool steel deposited specimen were examined via hardness and wear experiments as well as the observation of the morphology. Using the results of the examination of fundamental characteristics, the applicability of the DMT process to manufacture hot bulk forming die was discussed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.220-223
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• 2001

Until now, the clamp yoke of automobile has been largely manufactured by hot forging or burring process. Through the study, the precision cold forging process for clamp yoke has been analysed by using rigid-plastic finite element analysis code, DEFORM-3D. It has shown various results of the FEM simulation. An engineer should select the proper process considering the amount of product.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.11
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• pp.63-68
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• 2000

The purpose of this paper is to compare the forging effects according th the shape of preforms of cup shaped powder forging product, and extend the application of powder forging technology to more complicated cup-shaped products like pistons. In order to this, preforms are provided by compacting, sintering, and machining in various shapes, then forged to final shape of products. The workability for sintered aluminium powder material is examined. Density and strain loci of forged products are compared, and the most effective shape of preform is proposed. The preform for a piston of 50mm in diameter is provided and hot forged to final product.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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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.

• Transactions of Materials Processing
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• v.21 no.8
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• pp.473-478
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• 2012

The yoke, a component of conventional motor-driven power steering system, often contains welding defects from its manufacturing process. To eliminate these defects, the precision cold forging process has been tried. In this study, the double-action complex forging has been used to manufacture a torsion joint yoke. The backward extrusion proved faster than the forward extrusion in forging of the product. The double-action complex forging process utilized an upper die composed of a punch, a punch guide, a disc spring and a coil spring. The forged material pushes up the punch guide, and then the disc spring and the coil spring balances the backward extrusion force. Consequently, the flow of material was essentially in the forward direction, resulting in a successful forging operation. The forging load of Al 6061-T6 was higher than that of the automotive structural hot rolled plate.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.4
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• pp.653-659
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• 2017

In this study, the complex forging process of an outer support ring was developed and the prototype was manufactured. The current process, hot forging and MCT machining, has a disadvantage of excessive material removal rates and longer machining hours. To overcome this disadvantage, a general shape is given through hot forging and the precision is achieved through cold forging. The complex forging process was developed with the minimal machining process. Forging analysis was carried out to design a forging process using the commercial program, Deform-3D. The hot and cold forging processes were set up based on the analyzed result. The mold and prototype were manufactured. Hardness, surface roughness, internal defect, the grain low line of the prototype were evaluated. The results showed no particular problems, and there were no problems in mass production. Using complex forging, the material was reduced by approximately 27 % compared to the process using hot forging and MCT machining. In addition, the production speed was improved 2.15 fold compared to that of hot forging and MCT machining. Through this study, a cost-effective process and mold design technology were established, which is expected to have positive effects on other related automotive parts production.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.1 s.178
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• pp.185-192
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• 2006

A manufacturing process for a clutch gear which demands high strength and wear resistance, was developed by means of computer simulation. A preform was made by hot forging process and subsequent cold sizing process is applied to complete precise tooth part. Processes to obtain high dimensional accuracy and superior mechanical properties are analyzed and optimal heat treatment cycle to improve cold forgeability is introduced. Prototype was produced and the dimensional accuracy of the prototype was inspected to verify proposed process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1587-1590
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• 2005

A rigid-plastic finite element analysis for the die forging process of a socket ball joint, which is used in the transportation system, was carried out. And also with the results, the elastic stress analysis for the forging die was performed in order to get basic data for the die life prediction. The die fatigue life prediction was simulated using Goodman's and Gerber's equation. The prediction technique for the fatigue life of a forged product, the socket ball joint, using DEFORM-3D is presented and the results are commented upon. Archard's wear model was used for the wear simulation and then the wear simulation and then the wear quantity was quantity was evaluated using volume. In order to prove the wear simulation results to be reliable, wear quantity of the real forging die set in used a forging factory was measured using a 3-dimensional measurement apparatus. The simulation results were relatively in good agreement with the experimental measurements.