• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.03a
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• pp.171-174
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• 1997

In this study, a computer program was developed which generates automatically a drawing of the forging design in axisymmetric hot-forging of steel. The program designs a forging envelope from a machined part geometry according to forging design rules: parting line, draft angles, fillet and corner radii, minimum web and rib thicknesses. For the purpose of verification, the program was applied to a machined part from a factory. It was found that the generate forging design agreed well with the actual one used in the factory.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.3
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• pp.768-776
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• 1994

This paper describes computer-aided forging design for rib/web shaped parts. In manufacturing a part by means of forging process, the first step is to design the forging. This is done by modifying the given machined part geometry according to the requirements of the forging process. Traditionally, this is done by experienced forging designers using empirical forging design guidelines. Generally, it would be neither possible nor practical to develop a system which encompasses the design of all types of forgings. Accordingly, forging design can be simplified by considering critical two dimensional cross sections of the machined part geometry. This system is composed of three modules(process variable decision module, forging design module and redesign module) and each module is carried out in regular sequence. In the process variable decision module, first of all, the undercut is checked and modified, and then deep recesses and holes difficult to forge are eliminated. Also parting line, forging plane, forging plan view area, forging weight and maximum size(maximum height or width)are determined. In the forging design module, the magnitude of various allowances, draft angle, minimum web thickness, corner and fillet radius are determined and then geometry modification is performed. Finally, since the design rules and databases used in this system are based on parameters of the forging geometry, such as the trimmed forging plan area, forging weight, forging maxmum size, plausible estimates need to be made for these parameters. Therefore, in the re-design module, the design process is iterated until a satisfactory forging is obtained.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.186-189
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• 2001

In keeping with the needs of the times for energy and labor saving and simplifying production processes, interests has been growing in warm forging. Moreover, it is interested in increasing the material usage and production amounts. To improve the productivity and material usage, it is studied the process design of warm forging for socket. Until now, socket is manufactured by hot forging in hammer. The percentage of material usage is under $60\%$ in hammer forging. On the other han4 the percentage can be increased over $90\%$ in warm forging. To change the process from hot forging to warm forging, process designs must be performed. In this time, by using the FEM package, DEFORM-3D, we could get the shape of 1st process and minimum sealing pressure. They are very essential design data to decrease the trial and error. Practically, the overlap defect could be detected and eliminated with design modification of rib height and fillet radius. Moreover, forging load and minimum sealing pressure was defined by the 3D FEM analysis.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.10
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• pp.51-57
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• 1998

In this paper, a computer aided process design technique, utilizing a forging simulator and a commercial CAD software, is presented together with its related design system for cold-former forging of ball joints. The forging sequence design is carried out through user-computer interaction by using design templates, design database, experience or knowledge-based rules and some basic laws found in the literature. The forging simulation technique is used to verify the process design. The detail designs including die set drawings and die manufacturing information are automatically generated. It has been shown that the engineer ing and design productivity is much improved by the presented approach in the practical standpoint of process design engineers.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.04b
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• pp.178-182
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• 1995

The technique of neural networks is applied to cold forging design system. A user can select more desirable plans in cold forging design by being advised with expert's opinion from neural networks. The neural networks are learned with 3 parts which are most important in cold forging design-undercut, narrow hole, sharp corner. Using the neural networks, the cold forging design system built in this study determines forming possibility about variable shapes in product. We can get available result using the system.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.1
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• pp.91-97
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• 1996

This paper deals with a cold forging design system by which designers can determine desirable plans of cold forging design even if they have little experience. In this system, neural networks are used to transform qualitative knowledges to quantitative knowledges. The neural network is learned with three parts which are most important in cold forging design - undercut, narrow hole, sharp corner. The capabilities of the system are illustrated through an example of forging design.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.4
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• pp.83-90
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• 2018

In this research, we developed a process design hot-forging technology that precisely forms an inner race. The inner race transmits power to a one-way clutch of an automatic transmission and minimizes the CNC machining allowance. For a multi-stage hollow shape (inner race), we proposed several shapes of blocker and finisher for the precision hot-forging process and analyzed the forging process using DEFORM. The hot-forging process was optimized for several parameters, such as metal flow pattern, forging defect, and forming load. Blockers and finisher dies in the hot-forging process were designed to select optimal shapes from finite element analysis, and experiments were conducted to optimize the hot-forging process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.354-357
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• 2005

When Ti-6Al-4V is used in long steam turbine blades, the main issues are how to improve the fatigue strength as a problem of internal quality and how to forge the thinnest possible blades as problem of dimensional precision. To assure an excellent fatigue strength, it is important to make the two phase fine and equiaxial structure by providing enough plastic deformation in the two phase$(\alpha\;phase/\beta\;phase)$ temperature region. Accordingly, it needs to predict that forging temperature, preform design and forging velocity in forging process. To achieve this end, the two steps forging process was suggested to forge the thin and twisted blades with a precision hammer considering die forces and metal flow. Two steps forging process consists of the flattening forging process and finishing forging process. Process in forging of a 1016mm long steam turbine blade is designed by the finite element method. This study attempts to derive systematic design procedures for process design in the forging. Forging parameters was analyzed in two-dimensional plane-strain simulation and two steps forging process carried out in three-dimensional simulation. Consequently, optimal forging process parameters of long steam turbine blades in Ti-6Al-4V with a high dimensional precision are selected in the hammer die forging.

• 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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• 2003.10a
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• pp.47-50
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• 2003

Hot-forging Process and die design was made for a large-scale compressor wheel of Ti-6Al-4V alloy with 2-D FE analysis. The design integrated the geometry-controlled approach and dynamic materials modelling(DMM). In order to obtain the processing contour map of Ti-6Al-4V alloy based on DMM, compression tests were carried out in the temperature range of 915$^{\circ}C$ to 1015$^{\circ}C$ and the strain range of 10$\^$-3/s$\^$-1/ to 10s$\^$-1/. In the die design of the compressor wheel using the rigid-plastic FE analysis, forging dimensional accuracy, the capacity of the forging machine and defect-free forging were considered as main design factors. The microstructure of hot forged wheel using the designed die showed a typical alpha-beta structure without forging-defects.