• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2004년도 춘계학술대회 논문집
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• pp.87-90
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• 2004

In this paper, net-shape forming of an automobile gear is investigated. Barrel, a component of automobile start motor, is adopted as a net-shape forming. In order to accomplish the goal of net-shape forming without cutting of tooth and cam after forming, forming ability is raised through billet treatment and die design. As a technique of billet treatment spheroidizing annealing of billet to get low hardness and molybdenum disulphide coating to get low contact friction between billet and die is carried out. One of critical points of die design, fillet radii variation of tooth of die is applied to get smooth surface of barrel after cold forging. As a measurement of tooth accuracy, distance between two pins and lead-tooth alignments are investigated. Cam profile accuracy is checked with a 3D measuring instrument. Results obtained from the tests revealed reasonable result with respect to design goal. By these results, the paper shows that reasonable results can be obtained by billet treatment and die design for net-shape forming.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1997년도 춘계학술대회논문집
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• pp.155-158
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• 1997

The investigation deals with of a intermediate process condition hving a bolt-shaped final product where it is required to extend tool-life in forging. In this study, optimization of the design variables is conducted by a genetic algorithm, where the fitness values are evaluated on the basis of FEM analysis model. The approach is applied to the determination of the intermediate process conditions which are optimal with regard to minimization of peak die pressure.

• 한국정밀공학회지
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• 제19권2호
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• pp.195-202
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• 2002

An automated process planning system for cold forging of non-axisymmetric parts of comparatively simple shape was developed in this study. Programs for the system have been written with Visual LISP in the AutoCAD using a personal computer and are composed of four main modules such as input module, shape cognition and shape expression module, material diameter determination module and process planning module. The design rules and knowledges for the system are extracted from the plasticity theories, handbook, relevant reference and empirical knowledge of field experts. Generally, in forging, only front view is needed for expression of axisymmetric parts, but non-axisymmetric parts need front and plane view. At the plane, this system cognizes the external shape of non-axisymmetric, parts - number of sides of regular polygon and radius of a circle circumscribing the polygon of n sides. At the front view, the system perceives diameter of axisymmetric portions and height of primitive geometries such as polygon, cylinder, cone, concave, convex, etc.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1996년도 자동차부품 제작기술의 진보
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• pp.35-46
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• 1996

The powder forging process offers beneficial material utilization as well as the minimization of finishing operations over that of conventionally forged rods. In the present work, the sintering behavior of Fe-2Cu-0.6C-0.35MnS, optimum preform design and forgeability of various forging conditions were investigated. This data were generated using a newly proposed sub-scaled con-rod specimen developed specifically to simulate the powder forging process. The results of present work, powder perform is so difficult to flow material into die cavity and mass flow has no effect on improving the strength. And, applied force to increase density of the specimen flowed material is greater than that of all repessing mode. On the contrary, the specimen flowed material became increased hardness of inside in contrast with all repressing mode, but the tensile strength were decreased with residual porosity in surface. Due to material flow characteristic of powder preform, the section of lower density in powder preform became also lower density in forged con-rod. So, preform design is very important in manufacturing powder forged connecting rod.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2000년도 춘계학술대회논문집
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• pp.75-78
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• 2000

There are several effective factors to influence die life in the warm forging process. For instance process design die design and die materials etc This study presented heat treatment method which could improve toughness and wear resistance simultaneously in high temperature to apply high speed tool steels like SKH51 to die material for warm forging process. To verify the feasibility of application of heat treatment method mentioned above wear test was performed under the condition of constant time in 40$0^{\circ}C$ Wear coefficient was examined to search a relation between wear amount and time for each material and heat treatment method in 30, 60, and 130 minutes. To quantify the toughness-behavior between room and high temperature impact test was performed and heat fatigue test also fulfilled to compare with the resistance of heat check in room, 200, 400, and $600^{\circ}C$ temperature. On the basis of experimental results mentioned above high speed tool steel was applied to verify appropriateness of newly proposed heat treatment method for die of rotor pole used in automobile alternator. As a result die life of high speed tool steel applied newly proposed heat treatment is longer than that of STD61.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.434-437
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• 2007

Cold forging technology of a gear product is being interested in the dimensional accuracy, high stiffness and reduction of stress concentration. Especially it is needed to avoid the damage due to extremely high local pressure. Therefore it is important to ensure high pressure in die design. In this study, single die insert type and splitted die insert type are considered to recognize the notch effects in the die of sprocket forming. The stress concentration has been released at the notch area by the cushion effect in the splitted die insert.

• 한국자동차공학회논문집
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• 제25권1호
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• pp.111-115
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• 2017

This forged piston is proposed with a lighter weight and higher durability than a gravity casting piston for gasoline engines. However, a forged piston is very difficult to develop and mass-produce due to lack of basic technologies such as design, material and forging technique. First, we benchmarked existing forged pistons according to database design parameters. Second, we evaluated two solidification processes, continuous casting and spray forming, to produce heat-resistant alloy billets for forging. The spray forming process gives better mechanical properties at all temperatures, particularly at elevated temperatures except when poor formability is present. We used DEFORM simulation to determine the optimum process condition with billet from spray forming and successfully commercialized it with LF Sonata HEV.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2000년도 추계학술대회 논문집
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• pp.90-93
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• 2000

Al ally 7050 has been developed for higher strength and improved property against stress-corrosion cracking. Since the use of this alloy becomes more important for forged aircraft structural components. $\phi$ 65mm extruded billet has been forged for a highly-stressed aircraft parts. After forging processing and heat treatment, the forged parts showed undesirable microstructure caused by severe local grain coarsening at the surface layer and heavily-localized metal flow, the analysis of resulted in degraded mechanical properties. The above results have been compared to simulation by using the DEFORM-3D and those showed the thermomechamical processing must be optimized in terms of forging temperature, strain rate and deformation amount. To prevent the grain coarsening at the surface layer $\varepsilon$ heavily-localized grain flows.

• 한국정밀공학회지
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• 제12권11호
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• pp.118-124
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• 1995

In the paper, we have proposed a new technique to determine the initial billet for the forged products using a function approximation in neural network. A three-layer neural network is used and a back propagation algorithm is employed to train the network. An optimal billet which satisfied the forming limitation, minimum of incomplete filling in the die cavity, load and energy as well as more uniform distribution of effective strain, is determined by applying the ability of function approximation of the neural network. The amount of incomplete filling in the die, load and forming energy as well as effective strain are measured by the rigid-plastic finite element method. This new technique is applied to find the optimal billet size for the axisymmetric rib-web product in hot forging. This would reduce the number of finite element simulation for determining the optimal billet of forging products, further it is usefully adopted to physical modeling for the forging design

• 대한기계학회:학술대회논문집
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• 대한기계학회 2000년도 춘계학술대회논문집A
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• pp.780-785
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• 2000

The equi-potential lines designed in the electric field are introduced to find the preform shape in axisymmetric hot forging. The equi-potential lines generated between two conductors of different voltages show similar trends of the minimum work paths between the undeformed shape and the deformed shape. Base on this similarity, the equi-potential lines obtained by arrangement of the initial and final shapes are utilized fur the design of preform, and then the artificial neural network is used to find the range of initial volume and potential value of the electric field.