• Journal of Advanced Marine Engineering and Technology
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• v.28 no.1
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• pp.83-89
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• 2004

Flare nut is an important Part that used to joint a brake tube-end in automobiles. It was made of SWCH 10A by machining. But we studied to make it by metal forming. The main focus of this paper is to investigate an optimal forging processes for flare nut using the DEFORM$^{TM}$-3D. commercially available finite element code and tests. Actually an explicit finite element analysis of the flare nut forging processes has been carried out to predict an optimal shape of the flare nut and its results were reflected in the tests of the forging processes design for flare nut. The simulation results which had obtained from finite element analysis were contributed to the forging processes design for flare nut. An optimal shape of nave nut showed agreements with test results. Furthermore. this paper should contribute to a development of the forging process for a variety of parts.s.

• Transactions of Materials Processing
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• v.15 no.3 s.84
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• pp.183-188
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• 2006

Heat transfer coefficients have great influence on finite element analysis results in elevated temperature forging processes. Experimentally calculated contact heat transfer coefficient is not suitable for one-time finite element analysis because analyzed temperature will be appeared to be too low. To get contact heat transfer coefficient for one-time finite element analysis, tool temperature in operation was measured with thermocouple and repeated finite element analysis was performed with experimentally calculated contact and cooling heat transfer coefficient. Surface temperature of active tool was obtained comparing measurement and analysis results. Contact heat transfer coefficient for one-time finite element analysis was achieved analyzing surface temperature between repeated finite element analysis and one-time finite element analysis results.

• Transactions of the Korean Society of Mechanical Engineers
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• v.14 no.5
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• pp.1166-1180
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• 1990

The study is concerned with the two-dimensional thermo-viscoplastic finite element analysis for radial forging as an incremental forging process. The deformation and temperature distribution of the workpiece during radial forging are studied. The analysis of deformation and the analysis of heat transfer are carried out for simple upsetting of cylinder by decoupling the above two analyses. A method of treatment for heat transfer through the contact region between the die and the workpiece is suggested, in which remeshing of the die elements is not necessary. Radial forging of a mild steel cylinder at the elevated temperature is subjected to the decoupled finite element analysis as well as to the experiment. The computed results in deformation, load and temperature distribution are found to be in good agreement with the experimental observations. As an example of viscoplastic decoupled analysis of hot radial forging, forging of a square section into a circular section is treated. The stresses, strains, strain rates and temperature distribution are computed by superposing material properties as the workpiece is rotated and forged incrementally. It was been thus shown that proposed method of analysis can be effectively applied to the hot radial forging processes.

• Transactions of Materials Processing
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• v.13 no.2
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• pp.142-147
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• 2004

Three-dimensional rigid-plastic finite element analysis has been performed to optimize open die forging process to make round bar. In the round bar forging, it is difficult to optimize process parameters in the operational environments. Therefore in this study, finite element method is used to analyze the practice of open die forging, focusing on the effects of reduction, feeding pitch and rotation angle for optimal forging pass designs. The soundness of forging process has been estimated by the smoothness and roundness of the bar at various combination of feeding pitches and rotation angles. From the test result, process conditions to make round bar having precise dimensional accuracy have been proposed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.03a
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• pp.159-164
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• 1997

The optimal conditions were investigated in order to manufacture the light automotive body parts using the semi-solid forging process by the finite element nalysis. Considering about macro-segregation cause to difference of relative velocity between solid phase and liquid phase, solidificational phenomenon cause to heat transfer from die and export of the latent heat, so solid fraction updating algorithm can be proposed. The rigid thermo-viscoplastic finite element analysis was carried out according to die temperature with proposed algorithm, so availability of forming part were understood. The finite element program can be used to the analysis of semi solid forging process.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.5
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• pp.75-81
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• 2020

Multistage hot forging process enables mass production of various parts at a high speed, wherein, it is important to design the forging steps in an optimal way. Finite element methods are widely applied for optimizing the forging process design; however, they present inaccurate results due to the rapid change in the mold temperature during multistage hot forging. In this study, the temperature distributions of the mold in a steady state were calculated via heat transfer analysis during mold cooling. The flow stress and friction coefficient of the material were measured according to the temperature and were applied for numerical analysis of the multistage hot forging process. Eventually, the accuracy of the analysis results is verified by comparing these results with the experiments.

• Journal of Advanced Marine Engineering and Technology
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• v.32 no.4
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• pp.585-595
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• 2008

Process design of multi-stage forging for a bolt with nonaxisymmetric washer cam has been studied by using finite element method. For shape complexity of the bolt, it is impossible to manufacture in a single stage forging. To design multi-stage forging for the bolt the forging load and fiber flow of each step have been analyzed by using commercial finite element code DEFORM-3D. Simulated results have been compared with experimental ones. Multi-stage forging process has been designed with four stages. The workpiece should be eccentric shape until third forging stage. And then bolt head and washer of eccentrical shape is created in last stage. As a results, It was predicted that shape of product would be good and effective strain would be uniformly distributed in the product. Also, it was predicted whether defects would exist or not by reviewing the fiber flow.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.4
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• pp.677-682
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• 2012

For the product with small diameter, long column, and parabolic shape, the forging formability of the high-carbon steel wire rod was investigated in this study. By using the three-dimensional finite element method, the formability of wire was reviewed by forming analysis for the desired parabolic shape of local part. Analysis results due to forging direction, forging velocity, friction coefficient and constraint location were also investigated. On the basis of these results, it is noted that the forging direction has the big influence when the product with long column is forged. As the forging velocity increases, buckling tends to be limited and formability of parabolic shape is improved. By constraining the lower parabolic shape part to suppress plastic strain, the effect depending on friction coefficient is not almost appeared. And good parabolic shape is obtained at the region of the forging velocity of more than 0.5 m/s.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.1
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• pp.59-65
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• 2004

Hollow flange-shaped parts rue widely used in transportation systems. For good quality products, in general, design of preforms and die shapes for a progressive forging process is an important issue. For the design of die shapes for the forging process of a hollow flange, computer simulations Were earned out using the rigid-plastic finite element method. Forging defects like folding were seen in the vicinity of die corners at the typical shape ratios of upper and lower dies Die shape ratios at which the forging defect could occur during the extrusion-forging process of the hollow flange were investigated. The results might be efficiently used for the proper design of perform shapes, die shapes, and forging processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.86-89
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• 1999

Structural analysis of die set in cold forging is conducted by the finite element method and the results are introduced in this paper. The problem formulation is introduced in detail. In the approach, amount of shrink fit is controlled by thermal load, i.e., temperature difference between die insert and shrink fits. The loading conditions are extracted automatically from a forging simulator. An application example is given.