• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.406-409
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• 2005

In the forging operation of large ingot two break-down process are upsetting and cogging. The first purpose of upsetting is to ensure sufficient forging ratio for subsequent cogging operations and consolidate the voids along the centerline. The second purpose is related to improve the physical properties for a final product. Voids which are generated during the casting process can be one of the decisive defects of materials. So it is necessary to know the standard of Judgment for void-closure in upsetting operation. In practical conditions, FEM analysis(DEFORM 2D 8.1) was carried out to decide how much effective strain has influence on void-closure. It is finally suggested that the function consists of the effective strain of analysis data and the area rate of void.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.53-56
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• 2007

Computer simulation of microstructure evolution during hot forging process is of great interest in recent years. Recrystallization model and grain growth model which use a phenomenological approach were summarized. For the waspaloy, upsetting process and cogging process were simulated using $DEFORM^{TM}$ and the change in grain size were investigated in each deformation procedure.

• Proceedings of the KIEE Conference
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• 2006.04b
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• pp.170-172
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• 2006

This paper proposes a design method by varying rotor pole shape to reduce cogging torque, torque ripple and harmonics of back emf in Spoke type brushless DC(BLDC) motor. In the process of design and analysis, Response surface method(RSM) and finite-element method(FEM) are employed to get the rotor geometry and verify the results of new pole shape.

• Proceedings of the KIEE Conference
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• 2011.07a
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• pp.826-827
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• 2011

The selection of optimum parameters in electromagnetic design usually requires optimization of multimodal, non linear functions. This leads to extensive calculations which pose a huge inconvenience in the design process. This paper proposes a novel algorithm for dealing efficiently with this issue. Through the use of contour line concept coupled with Kriging, the algorithm finds out all the peaks in the problem domain with as few function calls as possible. The proposed algorithm is applied to the magnet shape optimization of an axial flux permanent magnet synchronous machine and the cogging torque was reduced to 79.8% of the initial one.

• Journal of Electrical Engineering and Technology
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• v.13 no.6
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• pp.2262-2267
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• 2018

In electric machine design, there is a large computation cost for finite element analyses (FEA) when analyzing nonlinear characteristics in the machine Therefore, for the optimal design of an electric machine, designers commonly use an optimization algorithm capable of excellent convergence performance. However, robustness consideration, as this factor can guarantee machine performances capabilities within design uncertainties such as the manufacturing tolerance or external perturbations, is essential during the machine design process. Moreover, additional FEA is required to search robust optimum. To address this issue, this paper proposes a computationally efficient robust optimization algorithm. To reduce the computational burden of the FEA, the proposed algorithm employs a useful technique which termed static analysis assisted technique (SAAT). The proposed method is verified via the effective robust optimal design of electric machine to reduce cogging torque at a reasonable computational cost.

• Transactions of Materials Processing
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• v.17 no.2
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• pp.113-116
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• 2008

Computer simulation of microstructure evolution during hot forging process is of great interest in recent years. Recrystallization model and grain growth model which use a phenomenological approach were summarized. The upsetting and cogging processes of waspaloy were simulated using $DEFORM^{TM}$ and the change in grain size were investigated in each deformation procedure.

• Transactions of Materials Processing
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• v.19 no.6
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• pp.329-336
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• 2010

Ring forging process is more appropriate for high-length and thin walled ring, because it utilizes the forging press and hence does not require heavy-duty ring rolling mill. Although ring forging process is very simple and economic for facilities, the process is not efficient because of multi-forging-step and low material utilization. An effective ring forging process is developed using a hollow ingot. When a hollow ingot is used with a workpiece, the ingot can be forged into a final ring without multi-stage pre-forging process, such as, cogging, upsetting, and piercing, etc.. Finally it has advantages of the material utilization and process improvement because a few reheating and forging process are not necessary to make workpiece for ring forging. The important design variables are the applied plastic deformation energy to eliminate cast structure and make uniform properties. In this study, the mechanical properties after forging of hollow cast ingot were investigated from the experiment using circumferential sectional model. Also, the effects of process variables were studied by FEM simulation on the basis of thermo-visco-plastic constitutive equation. Applied strain is different at each position in length direction because diameter of hollow ingot is different in length direction. The different strain distribution become into a narrow gap by additional plastic deformation during diameter extension process.

• Transactions of Materials Processing
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• v.21 no.5
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• pp.319-323
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• 2012

In order to predict the internal void closing behavior in open die forging process, multiple scale modeling has been developed and applied. The huge size difference between ingot and inner void makes it almost impossible to simultaneously model the actual loading conditions and the void shape. Multiple scale modeling is designed to integrate macro- and micro- models effectively and efficiently. The void closing behavior was simulated at 39 different locations in a large ingot during upsetting and cogging. The correlation between the closing behavior and variables such as effective plastic strain and maximum compressive strain was studied in order to find an efficient measure for predicting the soundness of the forging.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.377-380
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• 2006

Manufacturing process of Ti-6Al-4V alloy billet was investigated with FEM simulation and experimental analysis. Before the breakdown process of Ti-6Al-4V alloy ingot, FEM simulation for the breakdown processes of Ti-6Al-4V alloy ingot was used to calculate the forging load and state variables such as strain, strain rate and temperature. In order to breakdown the ingot structure and make an equiaxed structure billet, two different processes were employed for a VAR/VAR processed Ti-6Al-4V alloy ingot. Firstly, the ingot was cogged in single-phase $\beta$ field at the temperature of $1,100^{\circ}C$. In the process, the coarse and inhomogeneous structure developed by the double melting process was broken down. The second breakdown was performed by upsetting and cogging processes in $\alpha+\beta$ phase field to obtain the microstructure of fine equixed $\alpha$ structure in the matrix of transformed $\beta$. Finally, the mechanical properties of Ti-6Al-4V alloy billet made in this work were compared with those of other billet and ring product.

• The Journal of the Korea institute of electronic communication sciences
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• v.9 no.4
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• pp.527-536
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• 2014

In this paper, the 50kW aerogenerator which is applicable to the microgrid was designed and analyzed by using commercial simulation program Maxwell 2D. Particularly, the suggested PMSG to reduce the cogging torque introduced the offset and skew concept. The suggested optimal value of offset and skew was decided by 2mm and 60 degree of electric angle. The simulation results of the PMSG when load operation condition showed the average harmonic distortion 1.3%, voltage 322.41V, current 94.95A, and iron loss 9.73W, eddy current loss 73.68W, copper loss 3.52kW. The capacity of aerogenerator calculated 61.56kW, and the suggested design process can be applied to higher capacity generator.