• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 1996.05a
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• pp.219-226
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• 1996

일반적으로 밀폐 형단조공정에서 약 10,000톤의 성형력이 필요한 직경이 540mm인 플랜지 형태의 알루미늄 7175 합금 단조품을 2,500톤 프레스에서 단조하기 위한 공정연구를 하였다. 장비의 성형력 부족을 극복하기 위하여 업셋단조와 기계가공 및 전방압출을 조합한 복합성형공정을 제안하였으며, 복합공정은 실제재료를 이용한 $\frac{1}{4}$ 축소 모델 실험과 유한 요소 해석으로 그 타당성이 판단되었고, 선정된 프레스에서 실물 크기의 플랜지 단조 가능성을 확인하였다.

• 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.

• 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.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 1995.05a
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• pp.127-138
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• 1995

대형 복합재 연소관 금속 보스용 고강도 알루미늄 합금 7175-T74를 개발하기 위하여, 고순도 7175 합금을 이용하여 링롤 단조법으로 대형링을 제조하였으며, 열처리와 가공 조건을 정밀제어한 특수공정을 적용하여 기존의 재료와 재질 특성을 비교 분석하였다. 분석결과 특수공정의 7175S-T74는 기존의 7175-T74 및 7075-T73에 비해 2차상 입자의 분률이 작고, 동일한 SCC특성(38% IACS) 수준에서 강도와 파괴인성이 동시에 증가한 이상적인 강도-인성-SCC 조합특성을 가졌다. 이는 특수공정에서의 고온열처리에 의한 2차상 입자의 재고용과 그에 따른 석출량 증가 때문이며, 결국 7175 합금, 링롤단조 그리고 T74 특수공정을 조합 적용하면 구조적 신뢰성과 경제성 면에서 유리한 보스용 대형링을 개발할 수 있다.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.7
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• pp.1685-1696
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• 1994

In this paper, a new forming process of the large-size forgings within the limit of forming loads is developed by introducing the incremental forging method and combined forming method. For the development of the forming process, various related processes are proposed and modelling experiments of plasticine and corresponding numerical simulation ate carried out. Thus, an optimal process considering the productivity and economical efficiency is recommended from the study of formability and forming loads, etc. The selected process is subjected to a modelling experiment of lead and 1/7 scale prototype experiment of the real material so as to verify the effectiveness of a selected process as well as to determine the design parameters. The developed process is then applied the forging product of dome shape. Dome-shaped forgings can be produced by the developed process within the limit loads and with the simple tools.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.9 no.3
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• pp.69-75
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• 2010

A hollow flanged spindle is generally used for the assembly of the driving shaft in some vehicles. This part has conventionally been manufactured by both hot forging and machining process, in which case a circular billet is hot-forged into a flanged spindle blank and then its central part is machined for hollow. Therefore, the development of a new forming technology without further machining processes has strongly been in demand. In this study, a new compound forging process of the hollow flanged spindle was proposed through the finite element simulation. By the proposed compound forging process, both extruding of the spindle body part and piercing for the hollow inside it can be performed at the same time. Metal flow patterns, forging defects and forging forces were investigated through the finite element simulation results.

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

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.7 s.94
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• pp.1751-1760
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• 1993

The squeeze casting process is considered as an attractive way to form the primary product of near net shape metal matrix composites for wide use in automobile industry. To understand for infiltration limit in squeeze casting processes, the SAFFIL short fiber preform of volume fraction $10%{\sim}23%$ were fabricated by vaccum pumping and speed control press, and the optimal condition for fiber preform fabrication had been experimentally obtained. The composite materials were fabricated by forced infiltration of molten metals such as Al6061, Al7075, pure Al, AC8A, and Al2024. The infiltration distance and deformation of fiber preform are observed, and tensile strength were measured from at the room temperature.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.7 s.94
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• pp.1740-1750
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• 1993

The aluminar short fiber reinforced composite materials for hot extrusion were fabricated by semi-solid stirring method, and extruded at extrusion temperature $400^{\circ}C$ with various extrusion ratio. The hot extrusion load of volume fraction 15% metal matrix composites and base alloy Al7075 has been compared. The fiber length distribution, fiber breakage and fiber orientation are investiged to know the fiber behaviour in before and after hot extrusion. The tensile strength of the hot extruded billet are experimentally determined for different of extrusion ratios, and compared with theorically calculated strength.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.441-444
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• 2009

In this research, a hot and cold combined forging process for manufacturing net-shape one-way clutch bearing outer race of an automobile automatic transmission unit is developed. The process is composed of hot forging for manufacturing an optimized gear-like perform and precision cold forging for sizing the perform into final net-shape product. Finite element simulation techniques are applied to find the optimized process designs including blank and die shapes. The predictions and experiments are compared, revealing that they are in good agreement with each other. The dimensional test showed that the important dimensional requirements on gear tooth-like shape of the forged product were fulfilled.