• Journal of the Korean Society for Heat Treatment
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• v.14 no.2
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• pp.89-95
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• 2001

The 7175Al alloy is particularly interesting for its high strength and sufficient ductility, fracture toughness and corrosion resistance. Currently vigorous efforts have been made to develop large rockets usable for various purposes in the space. This has created the demand of big size of 7175Al billet which would be applied to heavy forgings. The aim of this study is to investigate the quality level of big billet and the effect of billet size on the mechanical properties of large 7175Al ring roll forgings. The billets range from 370 mm to 720 mm in diameter were homogenized and forged after direct chill casting. The size and volume fraction of second phase particles In ${\Phi}720$ mm billet are larger than those of ${\Phi}370$ mm billet, and its ductility is lower for the condition of homogenization and T6 treatment. The Cu-rich phases formed in interdendritic sites are considered to provide the preferential crack path during cold upsetting. The fracture toughness of ring roll forgings which are made by ${\Phi}370$ mm billet is higher than those of ${\Phi}720$ mm billet.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.3
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• pp.102-107
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• 2000

This study describes computer-aided design system for stepped asymmetric forgings. To establish the appropriate process sequence, an integrated approach based on a rule-base system was accomplished. This system has four modules, which are undercut prevention module, shape cognition module, 3D modelling module and corner/fillet correction module. These modules can be used independently or at all. The proposed shape cognition method could be widely used in forging design of asymmetric parts.

• Transactions of Materials Processing
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• v.6 no.6
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• pp.500-507
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• 1997

The conventional closed-die forgings had been applied to the forging of spur gears. But the forgings require high forging-pressure. In this paper, new precision forging technology have been developed. The developed technology is two steps forging process. Good shaped products are forged successfully with lower forging-pressure than those of conventional forging. The accuracy of the forged spur gear obtained by new precision forging technology is set nearly equal to that of cut spur gear of fourth and fifth class in Korean industrial standard.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.10a
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• pp.172-175
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• 1997

The conventional closed-die forgings had been applied to the forging of spur gears. But the forgings require high forging-pressure. In this paper, new precision forging technology have been developed. The developed technology is two steps forging process. Good shaped products are forged successfully with lower forging-pressure than those of conventional forging

• Transactions of Materials Processing
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• v.14 no.5 s.77
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• pp.423-431
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• 2005

In this paper, a systematic attempt for estimating geometric dimensions of cold forgings is made by finite element method and a practical approach is presented. In the approach, the forging process is simulated by a rigid-plastic finite element method under the assumption that the die is rigid. With the information obtained from the forging simulation, die structural analysis and springback analysis of the material are carried out. In the springback analysis, both mechanical load and thermal load are considered. The mechanical load is applied by unloading the forming load elastically and the thermal load is by cooling the increased temperature due to the plastic work to the room temperature. All the results are added to predict the final dimensions of the cold forged product. The predicted dimensions are compared with the experiments. The comparison has revealed that predicted results are acceptable in the application sense.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.192-198
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• 2005

In this paper, a systematic attempt for estimating geometric dimensions of cold forgings is made by finite element method and a practical approach is presented. In the approach, the forging process is simulated by a rigid-plastic finite element method under the assumption that the die is rigid. With the information obtained from the forging simulation, die structural analysis and springback analysis of the material are carried out. In the springback analysis, both mechanical load and thermal load are considered. The mechanical load Is applied by unloading the forming load elastically and the thermal load is by cooling the increased temperature due to the plastic work to the room temperature. All the results are added to predict the final dimensions of the cold forged product. The predicted dimensions are compared with the experiments. The comparison has revealed that predicted results are acceptable in the application sense.

• Korean Journal of Materials Research
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• v.14 no.3
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• pp.168-174
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• 2004

The aim of this study is to investigate the effect of process conditions on the microstructual changes and mechanical properties of large 7175 aluminum die forgings. The cast billets of 370 and 720 mm in diameter were homogenized and die forged after direct chill casting. The size and volume fraction of second phase particles in 720 mm billet were larger than those of 370 mm billet. The interdendritic sites containing the second phase particles was considered to be a crack initiation region in the process of cold upsetting. The tensile and yield strength of die forged specimens of 720 mm billet in the direction of Land L T were higher than those of 370 mm billet. However, the tensile strength of these specimens were 5 to 10% lower than that of American military specification. The plane strain fracture toughness of die forged specimens of 370 mm cast billet showed almost the same level of 720 mm billet, which was die forged after free forging.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.584-588
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• 1997

Lots of forginfs used in automobile and aerospce industries are made in hot or cold working conditions, depending on the size and shape of a product. Usually the die design for new items has been first made on the basis of experiences and many know-hows accumulated in the company and then slightly modified through trial and error method to get the desired forgings without defects. Most of drawings at the die design stage have been manually drawn, butrecently some of forging companies have begun to apply a computer-aided drafting technique to the die design for reducing drafting time as well as repeatedly utilizing standardized parts form registerd data base. In this paper the automated die design technique for forward extrusion of axisymmetric forgings is developed by using AutoLISP language. For this study the representative die system is determined form the investigation of several types of forging dies being currently employed in the metal forming field and the design rules for cold extrusion die are summarized and programmed on a personal computer. A few design examples of forward extrusion die are given and discusses.

• Transactions of Materials Processing
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• v.27 no.6
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• pp.370-378
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• 2018

Cold forging, carried out at room temperature, leads to high dimensional accuracy and excellent surface integrity as compared to other forging methods such as warm and hot forgings. In the cold forging process, WC-Co (Tungsten Carbide-Cobalt) alloy is the mainly used material as a core dies because of its superior hardness and strength as compared to other structural materials. For cold forging, die life is the most significant factor because it is directly related to the manufacturing cost due to periodic die replacement in mass production. To investigate die life of WC-Co alloy for cold forging, mechanical properties such as strength and fatigue are essentially necessary. Generally, uniaxial tensile test and fatigue test are the most efficient and simplest testing method. However, uniaxial tension is not efficiently application to WC-Co alloy because of its sensitivity to alignment of the specimen due to its brittleness and difficulty in thread machining. In this study, shape of specimen, tools, and testing methods, which are appropriate for uniaxial tensile test for WC-Co alloy, are proposed. The test results such as Young's modulus, tensile strength and stress-strain curves are compared to those in previous literature to validate the proposed testing methods. Based on the validation of test results it was concluded that the newly developed testing method is applicable to other cemented carbides like Titanium carbides with high strength and brittleness, and also can be utilized to carry out fatigue tests for further investigation on die life of cold forging.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.12
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• pp.105-113
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• 1997

In this study, the forging process of spur gears has been investigated. The forging process of spur gears has been classified into two type of operations, guiding one and clamping one in this investigation. Two type forgings of spur gears have been analysed by using upper bound method. The predicted values of the forging load were compared with those obtained from the forging experiments. The forging experiments were carried out with a commercial aluminium alloy. The forged parts obtained through the guiding type forging were campared with those obtained through the clamping type forging.