• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.5
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• pp.727-734
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• 1997

In practice, the design of forging processes is performed based on an experience-oriented technology, that is designer's experience and expensive trial and errors. Using the finite element simulation and the artificial neural network, we propose an optimal die geometry satisfying the design conditions of final product. A three-layer neural network is used and the back propagation algorithm is employed to train the network. An optimal die geometry that satisfied the same between inner extruded rib and outer extruded one is determined by applying the ability of function approximation of neural network. The neural networks may reduce the number of finite element simulation for determine the optimal die geometry of forging products and further they are usefully applied to physical modelling for the forging design.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.8
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• pp.57-64
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• 1997

The process design of backward and forward extrusion of axisymmetric part has been studied in this paper. The important factors of cold forging process with complex geometry are the design of initial billet shape, the possibility of forming by one-stage operation and the determination of preform shapes, etc. Based on the systematic procedure of process sequence design, the forming operation of cold forged part is analyzed by the commercial finite element program, DEFORM. The design criteria are forming load, geo- metrical filling without defect and a sound distribution of effective strain in final product. It is noted that one step of preform operation is required to obtain the final product. Numerical result is compared with experi- mental one. It is found that the analyzed result is in good agreement with actual forming result.

• Design & Manufacturing
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• v.14 no.3
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• pp.17-22
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• 2020

As devices such as smartphones, tablet PC, and wearable devices have been miniaturized, the connectors that go into the devices are also designed to be very small. The connector combines the plug and the receptacle to transfer electricity. As devices are miniaturized, the contact shape is formed by partially thinning the thickness of the raw material of the terminal in order to lower the coupling height of the plug and receptacle. The product used in this study is a receptacle terminal used for 0.4mm pitch board to board connector among fine pitch connectors. When the material thickness is reduced by forging the receptacle terminal, the width change of the pin is checked. To reduce the thickness of the material by forging, pre-notching is applied in the first step, forging in the second step, and notching in the third step. After forming the width dimension of the pin to 0.28 mm in the pre-notching process, in the forging process, the material thickness 0.08 mm and 0.02 mm (25%) were forged and the thickness was changed to 0.06 mm and the width change amount of the pin was measured. The facility produced 10,000 pieces at 400 SPM using a Yamada Dobby (MXM-40L) press, and thirty pins were measured and the average value was shown. After forging by using C5210-H (HP) and NKT322-EH, which are frequently used in connectors, analyze the amount of change in each material. The effect of punching oil on forging is investigated by appling FM-200M, which is highly viscous, and FL-212, fast drying oil. This study aims to minimize mold modification by predicting the amount of material change after forging.

• Transactions of Materials Processing
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• v.18 no.2
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• pp.150-155
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• 2009

A shaft for laser printers has to be produced with high dimensional accuracy of a few micrometers. Most companies produce the shaft, therefore, by machining. These days, forging process is tried to be employed in manufacturing the shaft for productivity. In this study, the dimensional inaccuracy of straightness is studied and the underfill is not focused because the shaft shape is simple and the load capacity of press is sufficient. The straightness and concentricity of the shaft is important for the operation of a laser printer. Many design parameters such as preform shapes, tooling dimensions, forging load, and billet geometries may affect on the dimensional accuracy. In the forging process of shafts, a billet which is cut from wires is used. The billet, therefore, may be a little bit curved but not always straight. The elastic recovery is considered to cause the dimensional inaccuracy. Therefore, the effect of the forging load on the elastic recovery and straightness is investigated through the finite element analyses using DEFORM-3D and ABAQUS.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.193-197
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• 2002

In this study, the casting/forging process was applied to the Shift-Fork, a manual transmission part of automobiles. In the casting experiments, the effects of additives, Sr, Ti＋B and Mg, on the mechanical properties and the microstructure of a cast preform were investigated. When 0.03% Sr were added into the molten aluminum alloy, the finest silicon-structure was observed in the cast preform and the highest tensile strength and elongation accomplished. And when 0.2% Ti＋B were added into the molten Al-Si alloy, the highest values of tensile strength were obtained. The maximum hardness was in case of 0.2% Mg. In the forging experiment, it was confirmed that the optimal configuration of the cast preform could be predicted by FE analysis. To minimize the cost as the press size, the compact shape of preform was proposed to reduce the volume of flash. The modification of shape in designing preform was performed to attain a satisfactory performance in the areas where the mechanical strength were more required. By using FVM(Finite Volume Method) software, it was verified that a proposed casting design was available. To identify the relationship between effective strain and mechanical properties of the final forged product, the compression test was performed. As the result, the tensile strength and elongation of a cast preform were much higher than before forging. The minimum forging temperature was found 40$0^{\circ}C$ to save heating time.

• Transactions of the Korean Society of Mechanical Engineers
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• v.13 no.3
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• pp.337-344
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• 1989

The upper bound elemental technique (UBET) is used to simulate the bulk flow characteristics in axisymmetric closed die forging process. Internal flow inside the cavity is predicted using a kinematically admissible velocity field that minimizes the rate of energy consumption. Application of the technique includes an assessment of the formation of flash and of degree of filling in rib-web type cavity using billets with various aspect rations. The technique considering bulging effect is performed in an incremental manner. The results of simulation show how it can be used for the prediction of forging load, metal flow, and free surface profile. The experiments are carried out with plasticine. There are good agreements in forging load and material flow in cavity between the simulation and experiment. The developed program using UBET can be effectively applied to the various forging problems.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.199-202
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• 2005

In this paper, the six sigma scheme is employed together with the rigid-viscoplastic finite element method to obtain the optimal metal flow lines in hot press forging. In general, the six sigma process is consisted of following five steps : define, measure, analyze, improve and control. Each step Is investigated in detail to meet customer's requirements through improvement of product quality. A forging simulator, AFDEX-2D, is used for analysis of the metal flow lines of a multi-stage hot forging process under various conditions of major factors, determined at each step of the six sigma process. The analyzed results are examined in order to reveal the effects of major factors on the metal flow lines and the formed shapes. The effects are used to find an optimal process and the optimal process with die is devised and tested. The comparison between required metal flow lines and experiments shows that the approach is effective for optimal process in hot forging design considering metal flow lines.

• Transactions of Materials Processing
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• v.32 no.1
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• pp.5-11
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• 2023

The aim of this study is to manufacture an aluminum pipe yoke of automotive steering system for lightweight. In a multistage cold forging process for aluminum pipe yoke, the surface defects frequently occur due to excessive deformation or friction during extrusion process for forming hollow pipe part. It is import to reduce the friction between the material and the forging die. This study investigated a multistage forging process with sliding die to reduce friction for aluminum pipe yoke. After evaluating by FE analysis, the forging experiment with the sliding die was carried out. As a result, it was possible to manufacture a sound aluminum pipe yoke.

• Journal of Advanced Marine Engineering and Technology
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• v.40 no.4
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• pp.314-319
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• 2016

Flange bolt has a circular flange under the head that acts like a washer to distribute the clamping load over a large area. Flange bolt has usually been manufactured by cold forging. Flower shape defect occurs in the flange forging stage. This defect causes lack of dimensional accuracy and low quality. So it is needed to improve these forging defects. In this study, die design method for flower shape defect of flange bolt was suggested. In order to improve flower shape defect, inner diameter of the addition die in conventional forging process was modified. The forging process with applied modified die was simulated by commercial FEM code DEFORM-3D. The simulated results for modified die were confirmed by experimental trials with the same condition.

• Transactions of Materials Processing
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• v.29 no.4
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• pp.194-202
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• 2020

In this paper, experimental and numerical study on a combined sheet metal forming and plate forging of a seal part of a passenger car's hub bearing is conducted to develop the new process of which target is to remove machining process by plate forging and to achieve near-net shape manufacturing. The previous process of a sheet metal forming inevitably needed a machining process for making stepped sheet after conventional sheet metal forming in a progressive way. The stepped sheet is intended to be formed by plate forging in this study. Through the systematic way of developing the combined forming process using solid elements based-elastoplastic finite element method (FEM), several conceptual designs are made and an optimized process design in terms of geometric dimensioning and tolerance of straightness of the thin part is found, which is exposed to bending in metal forming of axisymmetric part. The predicted straightness measured by the slope angle of the tilted thin region is compared with the experimental straightness, showing that they are in a good agreement with each other. Through this study, a systematic approach to optimal process design, based on elastoplastic FEM with solid elements, is established, which will contribute to innovating the conventional small-scaled sheet metal forming processes which can be dealt with by solid elements.