• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.171-177
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• 1995

In this paper, the deformation method for inner and outer races of rollr-bearing bymeans of the warm precision forging is investigated. We adapted the process designsuch as following that, toincrease Die life, reduce heat transfer through conduction and the eccentricity of preform in warm forging of bearing gace, the bottom portion of billet is formed during upsetting process. Then it is backward extruded, and thus obtained ring preform is formed by combined extrusion. Also, we compared it with the froming method in China and Japan, and we have known it is more excellent method. Basides, this forming method is simulated by UBST which is based on the merits of UBET nd FEM. The results show that it is easy to know the exact location of neutral surface through the inspection of streamline during combined extrusion, and the velocity vector distribution along the surface of velocity discontinuity is investigationed. Also the effectiveness of this method is proved by te experiment using model material that is Plasticine.

• Transactions of Materials Processing
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• v.8 no.3
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• pp.237-244
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• 1999

The purpose of this research is for the development of a new type forging equipment. H.C.G.(Hyundai Continuous Grain-Flow), by using two virtual build-up tools, rigid viscoplastic FEM and downsized plasticine experiment. This forging method consists of only vertical pressuree. Therefore, high quality crankshafts can be forged with this method as it can maintain a continuous grain flow. The factors considered in the development of equipment are die geometry for flawless deformed shape, die reaction forces, stress/strain distributions and continuous material flow. We carried out several numerical simulations and downsized plasticine experiments for the proper design of the forging equipment. The validity of those simulation results is confirmed by checking with the actual test results. Based on these simulation results, the proper design of the H.C.G. forging equipment is enabled.

• Transactions of Materials Processing
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• v.5 no.4
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• pp.305-319
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• 1996

In this paper a finite element based system is presented for the prediction of the distributions of the recrystallized grain sizes in the workpiece in hot forging. The system adopts a fully coupled finite element thermo-mechanical model for predicting plastic deformation and heat transfer occurring in the workpiece and employs existing metallurgical models relating the recrystalliza-tion behavior with the thermo-mechanical variables such as temperatures strain and strain rate. The system is applied to upsetting of cylindrical preform. The predicted grain sizes are compared with the measurements. It is further applied to forging of a complex-shaped product.

• Transactions of Materials Processing
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• v.6 no.4
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• pp.319-328
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• 1997

A flow stress involving strain, solid fraction, and breakage ratio, and solid fraction updating algorithm were proposed to depict the deformation behavior of materials at the semi-solid state. In case of isothermally simple upsetting of Sn-15%Pb alloy at the semi-solid state, by comparing the results of finite element analysis with the existing experimental results, the reliability of both the developed flow stress and updating algorithm were investigated. It was found that the verified program can effectively be used in the rigid-viscoplastic finite element analysis of the semi-solid forging processes.

• Transactions of Materials Processing
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• v.13 no.8
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• pp.696-703
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• 2004

The purpose of this study is to examine the bulk/sheet forming characteristics of bulk amorphous alloys in the super cooled liquid state. Recently it is reported that amorphous alloys exhibit stress overshoot/undershoot and non-Newtonian behaviors even in the super cooled liquid state. The stress-strain curves with the temperature-dependences as well as strain-rate dependence of Newtonian/non-Newtonian viscosities of amorphous alloys are obtained based on the previous experimental works. Then, those curves are directly used in the thermo-mechanical finite element analyses. Upsetting and deep drawing of amorphous alloys are simulated to examine the effects of process parameters such as friction coefficient, forming speed and temperature. It could be concluded that the superior formability of an amorphous alloy can be obtained by taking the proper forming conditions.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.129-134
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• 2009

The dimension of forged part is different from that of die. Therefore, a more precise die dimension is necessarys to produce the precise part, considering the dimensional changes from forging die to final part. In this paper, both experimental and FEM analysis are performed to investigate the effect of several features including die dimension at each forging step and heat-treatment on final part accuracy in the closed-die upsetting. The dimension of forged part is checked at each stage as machined die, cold forged, and post-heat-treatment steps. The elastic characteristics and thermal influences on forging stage are analyzed numerically by the DEFORM-$2D^{TM}$. The effect of residual stress after heat-treatment on forged part could be considered successfully by using DEFOAM-$HT^{TM}$.

• Journal of Magnetics
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• v.2 no.3
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• pp.67-71
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• 1997

A new hot-forming process has been studied to produce anisotropic Nd-Fe-B based magnets from melt-spun ribbons. The ribbon fragments were inserted in a Cu tube and hot-deformed together with one-stroke. At a height reduction ratio of 0.44, the melt-spun ribbons were densified into a magnet with a density of 7.14 g/cm3, and showed a (BH)max of 14.6 MGOe. With further deformation, the magnets were plastically deformed with Cu tubes in the lateral direction, and crystallographic anisotropy was introduced. The magnets with a height reduction ratio of 0.75 exhibited magnetic properties of (BH)max = 32.1 MGOe, Br = 11.7 kG, and iHc = 10.6 kOe. This process shows the possibility that the conventional hot-pressing and subsequent die-upsetting for anisotropic magnets can be simplified into a one-step process.

• Transactions of Materials Processing
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• v.3 no.3
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• pp.282-290
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• 1994

The outer race of BJ type C.V.Joint has a complicated shape and ball grooves. It is produced by cold or warm precision forging. Especially, the precision level of the ball grooves determines the quality of the part. The objective of the present study is to develop process conditions of the cold forging using the plasticine. Because the cold forging consists of forward extrusion, upsetting, backward extrusion and cold sizing, the study was focused on finding the best perform for each process. The data obtained from the study will be used in the design of the cold forging process for the outer race.

• Journal of Advanced Marine Engineering and Technology
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• v.18 no.4
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• pp.69-76
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• 1994

Thermal elasto-plastic analysis of axi-symmetric body by the finite element method is presented in this paper for analyzing the process of upset forming of circular section extruded bar. The example of calculation for upset forming of Nimonic extruded bar is also presented. It is shown that remeshing of quadrilateral finite element is necessary because the very highly distorted element by plastic deformation disturbs the calculation. Calculated values for nodal points in new mesh are obtained from nodal points of old mesh by linear interpolation method. The experimental results are compared with calculated values. The appearance of upsetupset forming obtained by experimental method is very similar to that obtained by calculations. So, it is proved that the thermal elasto-plastic analysis of axi-symmetric body by the finite element method is very useful for finding the optimum upsetting condition.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.2
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• pp.129-135
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• 1997

Experimental studies have been carried out to obtain uniform cups by one operation of backward extrusion. A lot of factors on dimensional accuracy of backward extruded cups are billet material, billet shape, punch shape, punch velocity, geometry of tool, tool material, and lubrication etc. In manufacturing cup-shaped parts by backward extrusion, it is very important to design the initial billet shape or the preform. The objective of this paper is to find that the shape of the initial billet is related to dimensional accuracy and also to manufacture the more accurate product simultaneously reducing the loss of material as forming the shape of the initial billet by means of upsetting.