• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.399-402
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• 2006

The outer race of CV(constant velocity) joint is an important load-supporting automotive part, which transmits torque between the transmission gear box and driving wheel. The outer race is difficult to forge because its shape is very complicated and the required dimensional tolerances are very small. Traditional warm and cold forging methods have their own limitations to produce such a complex shaped part; warm forging requires complex system with relatively higher manufacturing cost, while cold forging is not applicable to materials with limited formability. Therefore, multistage forging may be advantageous to produce complex shaped parts. In order to build a multistage forging system, it is necessary to characterize mechanical properties in response to system design parameters such as temperature, forging speed and reduction. For the analysis of formability of multistage forging process, finite element method(FEM) has been used for the process analysis. As a model case, a constant velocity (CV) joint forging process is analyzed by FEM, since CV joint has a complex shape and also its required dimensional tolerances are very tight. The data acquired by FEM is compared with operational forging data obtained from an industrial production line. Based on this comparative analysis, multistage forging process for CV joints is proposed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.1-9
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• 2003

The precision forging developed very fast in recent years due to the development of the automobile industry in China. Several actual examples are given to show this development and the direction of the precision forging in China should move forward is pointed out.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1995.03a
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• pp.41-53
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• 1995

Forging of spur gears has been investigated by means of upper-bound method. The term forging means forging of spur gears with solid cylindrical billets, hollow billets with flat punch. Kinematically admissbile velocity field for forging of spur gears has been proposed in this study. The 1/2 pitch of spur gear has been divided into seven dieformation regions, wherein, an involute curve has been introduced to represent the shape of die profile. Especially neutral surface has been introduced intor forging of hollow gears from hollow billets. By using the kinematically admissible velocity field, the powder requirements and suitable conditions for forging fo spur gears were successfully calculated with numerical method. According to the analysis , the acceptable number of teeth for forging of spur gears is from 15 to 20.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.325-328
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• 2004

This paper deals with void crushing behavior by ingot forging process which consists of sequential operations of upset forging and bloom forging. The predicted results of void crushing behavior by the simplified global-local method using F.E. analysis showed that the inherent void at the top region of the ingots remains incompletely crushed even after several forging operations. From the results of the hot upset forging test using the billets with drilled voids, it was found that the bonding efficiency of the void after forging process increases with an increase in deformation, and a decrease of initial diameter of voids.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.03b
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• pp.156-164
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• 1996

As high capacity and precision forging presses have become available, it is possible to manufacture gears by forging technology. In gear manufacturing by forging, however, there are problems of designs of ides and preforms. In the present paper, two exampels are presented to show how the rigid plastic finite element method can be utilized to overcome the problems. The examples are spur gear forging and interanl-apline gear forging. Both analyses are three dimensional using eight node linear block elements with approximation that the involute curve can be represented by lines and arcs. Results of the analyses include metal flow in dies and required load during forging which aid to decide proper designs.

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

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.67-72
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• 2003

The cold precision forging of spur gears has been researched, and the effects of relief-hole shape and forging process on the spur gears forming has been analyzed. The results present that the forging load decreases when a suitability diameter of relief-hole is chosen, but the function is not obvious. The spur gears precision forging method with an adjustable movement of concave mould can benefit both the top and the bottom comers forming of the spur gears, full fill the tooth cavity, and decrease the forging load.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.05a
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• pp.163-168
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• 2002

Hot forging is widely used in the manufacturing of industry machine component. The mechanical, thermal load and thermal softening which are happened by the high temperature in hot forging process. Tool life decreases considerably due to the softening of the surface layer of a tool caused by a high thermal load and long contact time between the tool and billet. Also, tool life is to a large extent limited by wear, heat crack and plastic deformation in hot forging process. These are one of the main factors affecting die accuracy and tool life. That is because hot forging process has many factors influencing tool life, and there was not accurate in-process data. In this research, life prediction of hot forging tool by wear and plastic deformation analysis considering tempering parameter has been carried out for automobile component. 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
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• 2005.10a
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• pp.326-329
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• 2005

Since the required strength of forged part is achieved by work hardening with the accumulation of plastic strain during the cold working, severe load can be exerted on die system. So, dies are liable to the early fracture for the non-heat treated steel forging in comparison with the conventional mild steels. Therefore, it is necessary to lower the flow stress of steels as much as possible during forging steps. Bauschinger effect can be utilized to lower flow stress during forging steps by giving the tensile prestrain on the forging billet during wire drawing step. In the present study, the prestrain effect on Bauschinger phenomenon is studied to avoid difficulties with application of non-heat treated cold forging steels in practice.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.75-77
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• 2007

Mg alloys have the highest specific strength which can be used industrial application. Since formability of Mg alloys is very limited, optimization of forming process is always needed for successful engineering application. In the present study. three different Mg alloys were used for hot forging processes and several process variables such as temperature and forging speed were investigated to improve forgeability of Mg alloys. To understand the effect of process variables in details, 2D-finite element analysis and forging experiment was performed. In the results, forging speed seems to be more important than forging temperature in hot forging of Mg alloys.