• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.199-203
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• 1995

The technology of Semi-Solid Forging (SSF) has been actively developed to fabricate near-net- shape products using light and hardly formable materials, the SSF process is composed of slug heating, forming, compression holding and ejecting step. After forming step in SSF, the slug is compressed during a certain holding time in order to be completely filled in the die cavity and be accelerated in solidification rate. The compression holding time that can affect mechanical properties and shape of products is important to make decision, where it is necessary to find overall hert transfer coefficeient properly which has large effect on heat transfer between slug and die. This paper presents the procedure to predict compression holding time of octaining the final shaped part with information of temperature and solid fraction for a cylindrical slug at compression hoiding step in closed-die compression process using heat transfer analysis considering latent heat by means of finite element method. The influence of the predicted compression hoiding time on mechanical properties of products is finally investigated by experiment.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.26-30
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• 2003

Since the dimension of cold forged part is larger than the cavity size of forging die, the difference results from the various features, such as, the elastic characteristics of die and workpiece, thermal influences, and machine-elasticity. All of these factors should be considered to get more accurate prediction of the dimension of forged part. In this paper, severe FE techniques are proposed to improve the prediction accuracy of dimension for cold forged part. To validate the importance of the above mentioned factors, and the estimated results are compared with the experimental results. The used model is a closed die upsetting of cylindrical billet. The calculated dimensions are well coincided with .the measured values based on the proposed techniques. The proposed techniques have put two simple but important points into Fe simulation. One is the separation of forging stages into 3 steps, from a loading through punch retraction to ejecting stage. The other is the dimensional change, according to the temperature changes due to the deformation. The FE analysis could predict the dimension of cold forged part within the $10{\mu}m$, based on the more realistic consideration.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.8
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• pp.63-72
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• 1995

Closed-die forging of spur gears with hollow cylindrical billet 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 the forging die profile. In the analysis, the deformation region has been divided into nine zones. A constant frictional stress has been assumed on the contacting surfaces. Utilizing the formulated velocity field, numerical calculations have been carried out to investigate the effects of various parameters, such as module, number of teeth and friction factor, on the forging of spur gears. Hardness and accuracy of forged gears are measured. The following results have been obtained: (1) It is verified that an axisymmetric deformation zone exists between root circle and center of gear through forged gears. (2) The average relative forging pressure is predominantly dependent on the number of teeth and increases near the final filling stage as the addendum modification coefficient increases. (3) Close agreement was found between the predicted values of forging load and those obtained from experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10c
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• pp.28-37
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• 2003

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1993.10a
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• pp.224-230
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• 1993

Closed-die forging of spur gears with hollow cylindrical billet has been analysed by using the upper-bound method. A kinematically admiccible velocity field has been developed. wherein, an involute curve has been introduced to represent the forging die profile. In the analysis, the deformation regions have been divided into nine zones. A constant frictional stress has been assumed on the contacting surfaces. Utilizing the formulated velocity field, numerical calcuations have been carried out to investigate the effects of various parameters, such as module, number of teeth and friction factor,on the forging of spur gears.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.777-781
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• 1997

In this study, the effect of strain-rate and inital solid fraction on the deformation behaviour of semi-solid material is investigated, when semi-solid forging is performed by the process of closed-die compression using A356 alloy of which the above results can be practically applied for industrical purpose. In order to simulate densification in the deformation of semi-solid material, the semi-solid material is assumed to be composed of solid region following rigid visco-plastic material, the liquid region following Darcy's law for the liquid flow saturated in the interstitial space. Simulation results of closed-die compression and simple upsetting under different strain-rate and initial solid fraction are compared.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.178-184
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• 2000

To obtain high quality component with thixoforming process, it is important that the homegeneous distribution of solid particles without liquid segregation. In closed-die semi-solid forging process, liquid segregation is strongly affected by injection velocity than any other process variables because the material has to travel relatively long distance to fill the cavity through a narrow gate before solidification begins. The optimal injection velocity and die temperature were investigated to fabricate near-net-shape compressor component called Al frame.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.03a
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• pp.209-217
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• 1994

The present study is concerned with the characteristics of the high speed precision bar cropping. This process is a practical application of High Energy Rate Forming in which the impact energy source is given by internal combustion engine. To enhance the added value of product, the recent forging fields trend toward the near net shape processes through the cold and closed die forging. For the purpose of these processes the precedent process is to obtain the precision billet which has little weight deviation and defect. The accuracy of initial billet by bar cropping depends upon the process parameters and die design technology. Therefore, in order to investigate the effect of process parameters upon product quality, the cropping experiments are carried out according to the various parameters such as billet clearence, billet length, billet material, cropping speed and so on. From these results some criteria of the optimal die design for the product of good quality are suggested.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.4 no.1
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• pp.36-41
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• 2003

The purpose of this study was to find a way to lengthen the life of hot closed forging die. The fluid interpretation on the plastic deformation of billet of billet was performed by finite element method. And design modification on the impression shape was also performed. The defaced part on the impression surface was mended by the developed build-up welding method. The die life was 3,000 units but alter the procedure it was lengthened up to 5,000.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.9
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• pp.2234-2244
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• 1994

A process sequence of multi-operation cold forging for actual application in industry is designed with the rigid-plastic finite element method to form a constant velocity joint housing(CVJ housing). The material flow during the CVJ housing forming is axisymmetric until the final forging process for forming of ball grooves. This study treats the deformation as an axisymmetric case. The main objective of the process sequence design is to obtain preforms which satisfy the design criteria of near-net-shape product requiring less machining after forming. The process sequence design also investigates velocity distributions, effective strain distributions and forging loads, which are useful information in the real process design.