• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2007.05a
• /
• pp.427-430
• /
• 2007

Gas turbine disk components have been used by Ni-base superalloys which have high temperature strength for enduring stress induced by high speed rotation. This study introduced the overview of development strategy of precision forging of turbine disk and closed-die forging process for manufacturing good quality gas turbine disk. To make superior quality turbine disk, it is important to select optimal forging process conditions like preform shape, die shape and forging temperature etc. In this paper, closed-die forging process has been studied through the rigid-plastic finite element simulation. Proposed forging process can be used for the successful manufacturing of small-size gas turbine disk.

• Transactions of Materials Processing
• /
• v.11 no.3
• /
• pp.211-216
• /
• 2002

The mechanical and thermal load, and thermal softening occuring by the rush temperature of die, in warm and hot forging, cause wear, heat cracking and plastic deformation, etc. This paper describes the effects of solid lubricants and surface treatments for warm forging die. Because cooling effect and low friction are essential to the long life of dies, optimal surface treatments and lubricants are very important to hot and warm forging process. The main factors affecting die hardness and heat transfer, are surface treatments and lubricants, which are related to heat transfer coefficient, etc. To verify the effects, experiments are performed for heat transfer coefficient in various conditions - different initial billet temperatures and different loads. Carbonitriding and ionitriding are used as surface treatments, and oil-base and water-base graphite lubricants are used. The effects of lubricant and surface treatment for warm and hot forging die life are explained by their thermal characteristics, and the new developed technique in this study for predicting tool life can give more feasible means to improve the tool life in hot forging process.

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

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.18 no.11
• /
• pp.2954-2966
• /
• 1994

The characteristics and good corrosion resistance at room and elevated temperatures led to increasing application of Ti-alloys such as aircraft, jet engine, turbine wheels. In forging of Ti-alloy at high temperature, die chilling and die speed should be carefully controlled because the flow stress of Ti-alloy is sensitive to temperature, strain and strain-rate. In this study, the forging of turbine disk was numerically simulated by the finite element method for hot-die forging process and isothermal forging process, respectively. The effects of the temperature changes, the die speed and the friction factor were examined. Also, local variation of process parameters, such as temperature, strain and strain-rate were traced during the simulation. It was shown that the isothermal forging with low friction condition produced defect-free disk under low forging load. Consequently, the simulational information will help industrial workers develope the forging of Ti-alloys including 'preform design' and 'processing condition design'. It is also expected that the simulation method can be used in CAE of near net-shape forging.

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

• Journal of the Korean Society for Precision Engineering
• /
• v.20 no.7
• /
• pp.26-35
• /
• 2003

This study explains the effects of lubricant and surface treatment on hot forging die life. The mechanical and thermal load, and thermal softening which is happened by the high temperature of die, in hot and warm forging, cause die wear, heat checking and plastic deformation, etc. This study is fur the effects of solid lubricants and surface treatment condition for hot forging die. Because cooling effect and low friction are essential to the long life of dies, optimal surface treatment and lubricant are very important to improve die life for hot forging process. The main factors, which affect die hardness and heat transfer, are surface treatments and lubricants, which are related to thermal diffusion coefficient and heat transfer coefficient, etc. For verifying these effects, experiments are performed for hot ring compression test and heat transfer coefficient in various conditions as like different initial billet temperatures and different loads. The effects of lubricant and surface treatment for hot forging die life are explained by their thermal characteristics. The new developed technique in this study for predicting tool life can give more feasible means to improve the tool life in hot forging process.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2006.05a
• /
• pp.386-390
• /
• 2006

In this paper, kinematic analysis of a double-action link-type die set for the enclosed die forging is carried out. Operational principle of the die set in the enclosed die forging is introduced in detail. A closed form solution of the relative velocity of the middle plate with respect to the upper plate is given. The effect of link lengths on both strokes and velocities is investigated.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 1998.10a
• /
• pp.242-247
• /
• 1998

The conventional closed-die forging processes had been applied to forging of the spur gears. But this type process requires high pressure. The commercial finite element analysis code ANSYS for the stress and elastic deformation of non-axisymmetric die was adopted in this study. In the non-axisymmetric die such as gear forging, maximum stresses were imposed on the tip of the gear tooth. When the stress exceeds yield strength of insert die, many approaches were attemped to prevent the die failure. Good shaped products are forged successfully. This type process could by used as an advanced technique to replace conventional hobbing process of gear.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.30 no.10 s.253
• /
• pp.1293-1297
• /
• 2006

In this paper, kinematic analysis of a double-action link-type die set for enclosed die forging is carried out. The structure of the die set and its operational principle during enclosed die forging are introduced in detail. A closed-form solution of the relative velocity of the middle plate with respect to the upper plate after the upper and lower dies are enclosed is given in terms of the link lengths and the distance from the lower pin to the upper pin of the link system. The effect of the link lengths on both strokes and velocities is investigated. It has been shown that the relative velocity of the middle plate with respect to the upper plate varies almost linearly with the stroke of the upper plate.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2003.05a
• /
• pp.191-194
• /
• 2003

A crank throw, which is one of the part of crankshaft for a large diesel engine, is manufactured by both closed die forging and open die forging. For the improvement of productivity the open die forging method is usually adopted to manufacture it these days. In case of the open die forging for the crank throw, a preform shape is very important because it seriously affects final dimensions of the product. The purpose of this study is to investigate affective factors of the preform to obtain a good shape of final product through simulation and the results are compared to downsized lead experiments.