• Transactions of Materials Processing
• /
• v.13 no.7
• /
• pp.635-641
• /
• 2004

Today the specific outputs of modern supercharger DI diesel engine for passenger cars reach values exceeding 50kw/1. By development of the articulated piston, specific output of up to 70kw/1 are sought. In doing so, peak cylinder pressure increases from the current 14-16MPa to 18-20MPa. The Articulated piston was composed Al cast skirt part and steel forged crown part. We have the target fer the design of forging process and die of the steel forged crown part. The design parameters of the forging process of the piston were obtained by the forging industry experiences and our experimental data and analysis result of finite element simulation. Especially, the design parameter of preform in blocker die was decided by finite element simulation using numerical package DEFROM3D. And also we can verify the design parameter by conducting visio-plasticity test using plasticine material. When we compared the results of analysis and experiment, a metal flow and load curve showed good agreement. Through this research, we could design optimal preform shape of articulated piston for this supercharged DI diesel engine.

• Transactions of Materials Processing
• /
• v.18 no.6
• /
• pp.444-447
• /
• 2009

Piston crown to the hot forge a unified nature of the product has a shape with multi-level step forging process, so if you are not a mechanical professional, this process could lead to a significant loss to the material. Therefore, material technology in minor terms; continue to improve the collection rate that undamaged the product material. The piston crown and the manufacturing products such as marine diesel engines are being forged to reduce costs and to improve mechanical properties. Piston crown molding is a hot forging process that works in large volume forging products. Because of the size of the hard plastic material flow process for improving the design and actual field experience through advanced plastic technology, it is important to interpret the results. Also for many experimental plastic procedures, the accumulation of results is very important.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2009.05a
• /
• pp.98-101
• /
• 2009

Piston crown to the hot forge a unified nature of the product has a shape with multi-level step forging process, so if you are not a mechanical process that can be a significant loss is material. Therefore, minor in terms of material technology; continue to improve the collection rate should be. The Piston crown and the manufacturing of products such as marine diesel engines, reducing costs and to improve mechanical properties of the method are being forged. Piston crown molding hot forging process the large volume forging products handling because of the size of the size of the hard plastic material flow process for improving the design and actual field experience through advanced plastic technology, and it is important to interpret the results and for many experimental plastic The accumulation of results is very important.

• Journal of the Korean Society for Precision Engineering
• /
• v.17 no.8
• /
• pp.53-59
• /
• 2000

In this study aluminum casting experiments are carried out to reduce the grain size of a cast preform and to spheriodize its dendritic structure by adding Ti+B and Zr and to modify flaked eutectic silicon by adding Sr, And a finite element simulation is performed to determine an optimal configuration of the cast preform to be used in forging of a compressor piston for an automobile air-conditioner. When 0.15% Ti+B Zr and 0.05% Sr are added respectively into the molten aluminum alloy the finest grain in casting of the preform is obtained. It is confirmed that the optimal configuration of the cast preform predicted by FEM simulation is very useful for forging the compressor piston. After forging the cast preform of the compressor piston. the microstructure and the hardness of the cast preform is compared with those of the cast/forged product.

• Transactions of the Korean Society of Automotive Engineers
• /
• v.25 no.1
• /
• pp.111-115
• /
• 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.

• Transactions of the Korean Society of Automotive Engineers
• /
• v.14 no.3
• /
• pp.44-50
• /
• 2006

The mono steel forged piston was improved a mechanical strength of an aluminum piston and reduced the weight of a articulated piston. The mono steel forged piston was composed of forged crown part and forged skirt part and was completed by friction welding process of two forged parts. Forging process analysis and friction welding analysis was done by finite element simulation using numerical package DEFORM. The preform shape and the initial billet dimension were decided by maximum stress of the die, amount of the flash and filling of die. The upset length of friction welding variable was decided by the shape of the flash that was created by friction welding analysis. Through this research, we developed a forging process of the mono steel forged piston, and decided the design variables of friction welding.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2008.10a
• /
• pp.197-198
• /
• 2008

The forging process produces complicated and designed components in a die at high productivity for mass production and minimizes the machining amount for favorable material utilization; the forging products used at highly stressed sections are well accepted at a wide range of industry such as automobile, aerospace, electric appliance and et cetera. Accordingly, recent R&D activities have been emphasized on improvement of forging die-life and near net shaping technology for cost effectiveness and better performance. Usually closing and consolidation of internal void defects in a ingot is a vital matter when utilized as large forged products. It is important to develop cogging process for improvement of internal soundness without a void defect and cost reduction by solid forging alone with limited press capacity. For experiments of cogging process, hydraulic press with a capacity of 800 ton was used together with a small manipulator which was made for rotation and overlapping of a billet. Size of a void was categorized into two types; ${\phi}$ 6.0 mm and ${\phi}$ 9.0 mm to investigate the change of closing and consolidation of void defects existed in the large ingot during the cogging process. In addition for forming experiment of piston grown air drop hammer with a capacity of 16 ton was used. The experiment with piston crown was carried out to show the formability and void closing status. In this paper systematic configuration for closing process of void defects were expressed based on this experiment results in the cogging process. Also forging defects through forming process for piston crown was improved using the experiment results and FE analysis. Consequently this paper deals with the effect of radial parameters in cogging process on a void closure far large forged products and formability of piston crown.

• Transactions of Materials Processing
• /
• v.3 no.2
• /
• pp.178-188
• /
• 1994

A design methodology is applied for manufacturing a disk-brake piston component. The design criteria are the limit drawing ratio and the forging load within the available press limit. Also, the final product should not have any geometrical defect. The rigid-plastic FEM has been applied to simulate the conventional four stage manufacturing processes, which include deep drawing and forging process. Simulation of one stage process from a selected stock to the final product shape is performed for generating information on additional requirements for metal flow. Two stage forming processes with different punch corner and nose geometries are also simulated to identify the possible best solutions. Finally, the best manufacturing process is selected, which is using a hemispherical punch int he deep drawing process.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1995.10a
• /
• pp.113-116
• /
• 1995

In this experimental study,aluminum hotforging was conduct to get superior pistion to cast piston. Cast structure of billet is destroyed, harmful defects is removed by forging process. We proposed the direction od die design by observing formability of product according to die shape. The microstructure of forged products with different preform was investigated to determine inital billet shape. We proposed appropriate heat treatment condition for improvement of mechanical properties.

• Transactions of Materials Processing
• /
• v.17 no.8
• /
• pp.600-606
• /
• 2008

In closed-die hot forging, a billet is formed in dies such that the flow of metal from the die cavity is restricted. Some parts can be forged in a single set of dies, whilst others, due to shape complexity and material flow limitations, must be shaped in multi sets of dies. The purpose of a performing operation is to distribute the volume of the parts such that material flow in the finisher dies will be sound. This study focused on the design of preforms, flash thickness and land width by theoretical calculation and finite element analysis, to manufacture the super hot forging product, 70MC type piston crown used in marine engine. The optimal design of preforms by the finite element analysis and the design experiment achieves adequate metal distribution without any defects and guarantees the minimum forming load and fully filling of the cavity of the die for producing the large piston crown. The maximum loads obtained by finite element analysis are compared with the results of experiments. The loads of the analysis have good agreements with those of the experiment. Results obtained using DEFORM-2D enable the designer and manufacturer of super hot forging dies to be more efficient in this field.