• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.144-149
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• 1996

In this paper, the clamping type forging of helical gears has been investigated. Clamping type forging is an operation in which the product is constrained to extrude sideways through an orifice in the container wall. Punch is cylindrical shaped. The punch compresses a cylindrical billet placed in a die insert. As a consequence the material flows in a direction perpendicular to that of punch movement. The forging has been analysed by using the upper-bound method. A kinematically admissible velocity field has been developed, wherein, an involute curve has been introduced to represent tooth profile of the gear. Numerical calculations have been carried out to investigate the effects of various parameters, such as module, number of teeth, helix angle, friction factor and initial height of billet on the forging of helical gears.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.183-186
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• 1995

A simulation method basee on upper bound method is developed in order to characterize forging characters in forging of spur gears. In this paer, utlizing a kinematically admissible velocity field and applying it to study the effect of inner diameter of holow billet. To predict the variation of inner diameter of hollow billet, neutal surface has been introduced into forging of hollow gears from hollow billes with flat punch. The neutral surface of each step is assumed as a circle and determined in order to have minimum forging energy by golden section method. According to the analysis, the magnitude of inner diameter of initial billet is vary important to reduce the relative pressure and forging load. And the variation of inner diameter of billet during spur gear forging is successfully predicted.

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.5
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• pp.653-660
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• 1986

Two uppor bound solutions, by the force balance method and by a kinematically admissible velocity field, are compared for the metal forming problems in plane strain. It is concluded that these two approaches always give identical results when the geometrical configurations of the deformation model reman the same. By detailed derivations for plastic bending of a notched bar, closed die forging, compression of a rectangular block, machining with a restricted contact tool and plane strain backward extrusion, the identity of both approaches is verified.

• Transactions of the Korean Society of Mechanical Engineers
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• v.13 no.3
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• pp.330-336
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• 1989

In analyzing the axisymmetric backward extrusion process a new method of analysis using upper-bound theorem is proposed in which the plastic zone and dead metal zone cam be predicted. Experiments are carried out with commercial aluminum. The metal flow on the meridional plane has been visualized experimentally by using the gridded specimens. It is shown that the theoretical results both in extrusion load and deformation pattern are in good agreement with the experimental results and they can be used for effective punch and die design to consider various process parameters in axisymmetric backward extrusion.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.9
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• pp.110-116
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• 1999

A new KAVF(kinematically-admissible velocity field) is proposed to determine the forming load, the average extruded length and the flow pattern is the extrusion/forging process of polygonal headed bars. Experiments are carried out with lead billets at room temperature using regular polygonal shaped punches. The theoretical predictions of the forming load and the average extruded length are in good agreement with the experimental results.

• Journal of the Korean Society for Precision Engineering
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• v.10 no.2
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• pp.40-47
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• 1993

To diversify the area of application of UBET to the analysis of ring rolling which produces rings having more complex cross-sectional configuration, an element of triangular cross-section has been introduced and the corresponding kinematically admissible velocity field has been derived while considering the material flow between neighboring elements. The theoretical perdictions in roll torque and profile formation show good agreement with the experiments. The effect of process parameters such as feed rate and taper angle of the roll groove has been discussed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.9
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• pp.1364-1372
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• 1997

In this paper, the forging of helical gears has been investigated. Punch is tooth-shaped as is the die insert. The punch compresses a cylindrical billet placed in a die insert. As a consequence the material of billet flows into the tooth region. The forging has been analysed by using the upper-bound method. A kinematically admissible velocity field has been developed, wherein, an involute curve has been introduced to represent tooth profile of the gear. Numerical calculations have been carried out to investigate the effects of various parameters, such as module, number of teeth, helix angle and friction factor on the forging of helical gears. Some forging experimentswere carried out with aluminum alloy to show the validity of the analysis. Good agreement was found between the predicted values of the forging load and obtained from the experimental results.

• Transactions of Materials Processing
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• v.8 no.4
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• pp.374-383
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• 1999

To determine the flow stress of semi-solid materials, a new combined method has been studied by experimental and analytic technique in the current approach. Using backward extrusion experiment and its numerical analysis, the characterization scheme of semi-solid materials according to the change of initial solid volume fraction has been proposed. Because that solid volume fraction is sensitive to temperature change, it is required to precisely control the temperature setting. Model materials can guarantee the establishment of material characterization technique from the noise due to temperature change. Thus, clay mixed with bonded abrasives was used for experiment and the change of initial solid fraction was copied out through the variation of mixing ratio. Upper bound method was adapted to increase in efficiency of the calculation in numerical analysis and new kinematically admissible velocity field was employed to improve the accuracy of numerical solution. It is thought that the material characterization scheme proposed in this study can be applied to not only semi-solid materials, but also other materials that is difficult to obtain the simple stress state.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.11
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• pp.1827-1836
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• 1997

In this paper, the clamping type forging of helical gears has been investigated. Clamping type forging is an operation in which the product is constrained to extrude sideways through an orifice in the container wall. Punch is cylindrical shaped. The punch compresses a cylindrical bilet placed in a die insetr. As a consequence the material flows in a direction perpendicular to that of punch movement. The forging has been analysed by using the upper-bound method. A kinematically admissible velocity field has been developed, wherein, an involute curve has been introduce to re4present tooth profile of the gear. Numerical calculations have been carried out to investigate the effects of various parameters, such as module, number of teeth, helix angle, friction factor and initial height of billet on the forging of helical gears. Some firgiing experiments were catrried out with aluminium alloy to show the validity of the analysis. Good agreement was found between the predicted values of the forging load and obtained from the experimental results.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.5
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• pp.98-104
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• 2020

Pipe expansion involves various methods to enlarge the diameter of the pipes with the use of a mandrel or punch placed inside the pipe. In this study, the upper bound method was used to analyze the pipe expanding process as well as design a die. A kinematically admissible velocity field was derived for the upper bound analysis with the occurrence of pipe thinning during the expansion factored in. The analysis confirms that a semi-cone angle of the punch between 15ween pip is most advantageous for pipe expansion. The results of the upper bound analysis, which were also consistent with those of the FEM, can be useful for the design of a pipe expansion die.