• Transactions of Materials Processing
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• v.9 no.2
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• pp.159-164
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• 2000

In this paper, a computer simulation technique for the forging process having a floating die is presented. The penalty rigid-plastic finite element method is employed together with an iteratively force-balancing method, in which the convergence is achieved when the floating die part is in force equilibrium within the user-specified tolerance. The force balance is controled by adjusting the velocity of the floating die in an automatic manner. An application example of a three-stage cold forging process is given.

• Transactions of Materials Processing
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• v.8 no.4
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• pp.384-392
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• 1999

In metal forming, there are problems with recurrent geometric characteristics without explicitly prescibed boundary conditions. In such problems, so-called recurrent boundary conditions must be introduced. In this paper, as a practical application of the proposed method, the precision cold forging of a helical gear has been simulated by a three-dimensional rigid-plastic finite element method and compared with the experiment. The application of recurrent boundary conditions to helical gear forging analysis is proved to be effective and valid. the elastic stress analysis of the die for helical gear forging has been calculated by using the nodal force at the final stage obtained from the rigid-plastic finite element analysis. In order to obtain more precise gear products, the elastic analysis of the die after release of punch and the elastic spring-back analysis of product after ejection have been performed, and the final dimension of the computational product has been in good agreement with that of the experimental product.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.369-372
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• 2006

Monolithic forging of cask is required continuously. Body-base monolithic forging of cask has advantage of an economical manufacturing process and better reliability for nuclear applications. Through the finite element analysis and parametric study of design variables, those are die angle, groove length and flange thickness, the optimal dimensions of preform and die sets are determined in order to develop a suitable forging process for body-base monolithic forging. To verify the result of finite element analysis, the physical model of 1/30 scale of actual product using plasticine was carried out. The result of this experiment, deformed shapes were very similar to the finite element analysis. As a result of this work, the special piercing method was developed using blank material consisting of a flange, groove and squared part.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.88-91
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• 2003

The forging of Al 6061 has been studied by using finite element analysis and real forging experiment to find out the effect of strain rate and strain on the final forged product. It seems to be well known that the mechanical properties depend on the microstructures of forged products. The hot deformation of Al alleys including Al 6061 has been researched quite a long period on the various aspects. However, the forging of Al alloys seem to have few information, especially the recrystallization, recovery and grain growth. To elucidate the process variables to control those microstuctual aspects the specially designed model was used for finite element simulation and forging experiments, in which the variation of strain and strain rate could be obtained. The effect of strain md strain rate has been related with the microstructures of forging stocks.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.10 no.10
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• pp.2577-2582
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• 2009

A rivet which can fasten two parts is one of an important mechanical elements. In this study, the process design of a blind revet is implemented using finite element method in order to manufacture it which can resist high vibration and has strong coherence between two parts. Considering plastic flow, ease of manufacture, high strength, material loss, and so forth, an optimal four-stage process is proposed by finite element analysis and process design rules. In addition, the finite element simulation results such as shape of the forged rivet, strain distribution and forging load are investigated for the usefulness of the forging process of the blind rivet. These results will be contributed to the forging process design and the die design of the blind rivet.

• Transactions of Materials Processing
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• v.28 no.2
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• pp.98-104
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• 2019

The present study numerically simulates the deformation heterogeneity developed in AA1100 during multi-axial diagonal forging (MADF) using finite element analysis (FEA). Diagonal forging type consisting of diagonal forging (DF) and return-diagonal forging (R-DF) proved to be relatively beneficial compared to plane forging type which includes plane forging (PF) and return-plane forging (R-PF) for minimizing the non-uniformity of deformation developed in workpieces. Simulation of the effective strain generated in workpieces during the two types of forging was done using 3-D FEA. FEA shows the effect of friction coefficient on the deformation behavior on workpieces. The simulation of 2 types forging with different friction coefficients revealed that the magnitude of barreling effect and strain heterogeneity in workpieces increases with an increase in the friction coefficient.

• Journal of Powder Materials
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• v.5 no.1
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• pp.57-63
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• 1998

The densification behaviors of rapidly solidified Al-Si alloys under high temperature processing were investigated. In general, it was difficult to establish optimum process variables for forging condition through experimentation, because this was costly and time consuming. In this paper, to overcome these problems, we compared the experimental result to the finite element analysis for forging processes of rapidly solidified Al-Si alloys. The results of these simulations helped understand the distribution of relative density during various forging processes. This information is expected to assist in improving rapidly solidified Al-Si alloys forging operations.

• Transactions of Materials Processing
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• v.7 no.4
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• pp.347-353
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• 1998

A new approach of elastic finite element to die stress analysis in forging is presented in this paper. The die set analysis problem is formulated by considering contact problems under both mechanical and thermal loads. 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. The predicted solution is compared with analytical one and it has been shown that the predicted results are in excellent agreement with the analytical ones. An application example is given, which was found in a cold forging company.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.1
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• pp.92-99
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• 2003

Bevel gears are important mechanical parts to transmit power in transportation system high precision parts like bevel gears might be manufactured by closed die forging process for dimensional accuracy. Closed die forging of bevel gears offers the high quality and good mechanical properties and also leads to considerable cost saving. To determinate the proper closed-die forging process for bevel gear forms, three-dimensional finite element simulation for the progressive forging process was earned out and also the simulation results were compared with experimental results.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.1
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• pp.67-73
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• 2011

In this study, the manufacturing technology of a folding blind rivet was developed through finite element analysis(FEA). Numerical simulations of the folding blind rivet used to join two components have been performed with the finite element method for the forging process design. To minimize the process and manufacture the folding blind rivet without defects, a variety of design rules were proposed. From the results of FEA applied process design rules, an optimal six-stage process was proposed. The finite element simulation results such as shape of the forged rivet, strain distribution and forging load were investigated for the usefulness of the forging process of the blind rivet. In addition, the experiments have been implemented and their results were compared to the analytic results.