• 한국정밀공학회지
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• 제16권9호
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• pp.96-103
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• 1999

A kinematically admissible velocity field is derived to analyze the forming load and the extruded length in the extrusion/forging process of trochoidally headed bars from round billets. The forming load and the extruded length are obtained by minimizing the total energy-consumption rate. Experiments are carried out with lead billets at room temperature using trochoidally shaped punches. The theoretical predictions of forming load and extruded length are in good agreement with the experimental results.

• 한국재료학회지
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• 제10권9호
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• pp.629-635
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• 2000

본 논문에서는 Ti-48.5at%Al-0.96at%Mo 조성을 갖는 $\gamma$-TiAl 합금은 항온 단조 및 후속 조직제어 열처리 시 발달하는 집합조직의 변화에 관해 연구하였다. 특히, 동적 재결정 후 조직제어 열처리 온도와 시간의 증가에 따라 발생하는 lamellar volume fraction 과 집합조직 변화에 주목하여 관찰하였다. 동적 재결정 후 집합조직은 ND$\perp${302) 선분과, TD$\perp${100) 및 이에 비해 상대적으로 다소 약한{111) 성분들이 발달하였으며, 열처리 온도와 시간이 증가함에 따라 lameller volume fraction 은 증가했고 동일한 성분의 집합조직도 점차 강하게 발달함을 알 수 있었다. 하지만 상온인장시험 결과는 lameller volume fraction이 증가할수록 낮은 상온 연신을 보였는데, 이는 준 층상조직을 갖는 $\gamma$-TiAl합금의 상온인장특성이 집합조직의 영향보다는 lameller volume fractio과 같은 미세조직 특성에 더욱 강하게 영향을 받기 때문인 것으로 판단된다.

• 한국분말야금학회:학술대회논문집
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• 한국분말야금학회 1997년도 추계학술강연 및 발표대회 강연 및 발표논문 초록집
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• pp.7-7
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• 1997

During sintering of very porous green bodies, as obtained by compaction of hard powders - such as tungsten carbide or ceramics - or by injection moulding, important shrinkage occurs. Due to heterogeneous green density field, gravity effects, friction on the support, thermal gradients, etc., this shrinkage is often non-uniform, which' may induce significant shape changes. As the ratio of compact dimension to powder size is very high, the mechanics of continuum is relevant to model such phenomena. Thus numerical techniques, such as the finite element method can be used to simulate the sintering process and predict the final shape of the sintered part. Such type of simulation has much been developed in the last decade firstly for hot isostatic pressing and next for die compaction. Finite element modelling has been recently applied to free sintering. The simulation of sintering should be based on constitutive equations describing the thermo-mechanical behaviour of the material under any state of stress and any temperature which may arise within the sintering body. These equations can be drawn either from experimental data or from micromechanical models. The experiments usually consist in free sintering and sinter-forging tests. Indeed applying more complex loading conditions at high temperature under controlled atmosphere is delicate. Micromechanical models describe the constitutive behaviour of aggregates of spheres from the deformation of two-sphere contact either by viscous flow or grain boundary diffusion. Such models are not able to describe complex microstructure and mechanisms as observed in real materials but they can give some basic information on the formulation of constitutive equations. Practically both experimental and theoretical approaches can be coupled to identify the constitutive equations. Such procedure has been performed for modelling the sintering of compacts obtained by die pressing of a mixture of tungsten carbide and cobalt powders. The constitutive behaviour of this material during sintering has been described by a linear viscous constitutive model, whose functions have been fitted from results of free sintering and sinter-forging experiments. This model has next been introduced in ABAQUS finite element code to simulate the sintering of heterogeneous green compacts of various geometries at constant temperature. Examples of simulations are shown and compared with experiments.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.160-164
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• 2007

In the steel industry, there is a need to produce large forged parts for the automobile industries, the flight and shipping industries ad military industries. In the steel-industry application, a cogging technique for cast ingots is required, because the major parts are needed as one large body in order to obtain higher quality. Therefore, cogging process is the primary step in manufacturing of practically large open-die forging. In the cogging process, internal voids have to be eliminated as defects, The present work is concerned with the elimination of the internal voids in large ingots so as obtain sound products. In this study, hot compression tests were carried out to obtain the flow stress of cast microstructure at different temperature and strain rates. The FEM analysis are performed to investigate the overlap defect of cast ingots during cogging stage. The measure flow stress data were used to simulate the cogging process of cast ingot using the practical material properties. Also the analysis of void closure are performed by using the $DEFORM^{TM}$-3D. The calculated results of void closure behavior are compared with the measured results before and after cogging, which are scanned by the X-ray scanner. From this result, the criteria for deformation amounts effect on the void closure can be investigated by the comparison of practical experiment and numerical analysis.

• 소성∙가공
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• 제16권2호
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• pp.126-131
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• 2007

Voids in a large rotor are formed in solidification process of a cast ingot. The voids have to be eliminated from the rotor by a forming process, because they would became stress-intensity factors which suddenly fracture the rotor in the operation. Previous studies on void-elimination of a large rotor have mainly focused on finding the process variables affecting the void-closure. But the study on the amount of void closure in a large rotor has been very rare. This study was performed to obtain an equation which predicts the amount of void-closure in a forging process of a large rotor and to evaluate the availability of the void-closure equation through finite element analyses. Firstly, 2D FE analysis was carried out to find effects of time integral of hydrostatic stress and effective strain on void volume rate of a large rotor in the upsetting process for various diameters and shapes of void, and material temperature. From the 2D FE analysis, we found that effective strain was suitable for predicting the void-closure of a large rotor, because there was a constant relationship between void volume rate and effective strain. And a void-closure equation was proposed fur predicting void-closure of a large rotor in the upsetting process. Finally, ken the 3D FE analysis, the proposed void-closure equation was verified to be useful for upsetting and cogging processes.

• 소성∙가공
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• 제22권8호
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• pp.463-469
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• 2013

In the previous work, a new forging process design, which included incremental upsetting, diffusion bonding and cogging, was suggested as a method to manufacture 1.9wt%C ultrahigh carbon workrolls. The previous study showed that incremental upsetting and diffusion bonding are effective in closing voids and healing of the closed void. In addition, compression tests of the 1.9wt%C ultrahigh carbon steel revealed that new microvoids form within the blocky cementite at temperatures of less than $900^{\circ}C$ and that local melting can occur at temperatures over $1120^{\circ}C$. Thus, the forging temperature should be controlled between 900 and $1120^{\circ}C$. Based on these results, incremental upsetting and diffusion bonding were used to check whether they are effective in closing and healing voids in a 1.9wt%C ultrahigh carbon steel. The incremental upsetting and diffusion bonding were performed using sub-sized specimens of 1.9wt%C ultrahigh carbon steel. The specimen was deformed only in the radial direction during the incremental upsetting until the reduction ratio reached about 45~50%. After deformation the specimens were kept at $1100^{\circ}C$ for the 1 hour in order to obtain a high bonding strength for the closed void. Finally, microstructural observations and tensile tests were conducted to investigate void closure behavior and bonding strength.

• 한국재료학회지
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• 제25권10호
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• pp.552-558
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• 2015

The mechanical properties and microstructures of Aluminum 6056 alloys were investigated for their use in the fabrication of a piton block. The EN-AW6056 alloys exhibited a tensile strength of 375 MPa for a solution treatment temperature of $550^{\circ}C$ for 2 h followed by an aging treatment at $190^{\circ}C$ for 4 h. The microstructures of the heat treated specimen showed that the $Mg_2Si$ phase with a size of 3~5 um was dispersed throughout the aluminum matrix when the heat treatment was done. Moreover, in order to identify the forgeability of the specimen, upsetting tests were done. For up to 80 % of the upsetting ratio, the specimen maintained its original shape, and at above 80 % of the upsetting ratio, the specimen underwent crack development. The specimen was successfully forged without any defects with the examined material conditions. The material conditions together with the forging conditions are discussed in terms of the microstructures and mechanical properties.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 추계학술대회 논문집
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• pp.589-592
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• 2005

Micro-forming is a suited technology to manufacture very small metallic parts(several $mm{\sim}{\mu}m$). Micro-forming of $Zr_{62}Cu_{17}Ni_{13}Al_8$ bulk metallic glass(BMG) as a candidate material for this developing process are feasible at a relatively low stress in the supercooled liquid state without any crystallization during hot deformation. In this study, micro-formability of a representative bulk metallic glass, $Zr_{62}Cu_{17}Ni_{13}Al_8$, was investigated for micro-forging of U-shape pattern. Micro-formability was estimated by comparing $R_f$ values $(=A_f/A_g)$, where Ag is cross-sectional area of U groove, and $A_f$ the filled area by material. Microforging process was simulated and analyzed by applying finite element method. FEM simulation results should reasonable agreement with the experimental results when the material properties and simulation conditions such as top die speed, remeshing criteria and boundary conditions tightly controlled. The micro-formability of $Zr_{62}Cu_{17}Ni_{13}Al_8$ was increased with increasing load and time in the temperature range of the supercooled liquid state. Also, FEM Simulation using DEFORM was confirmed to be applicable for the micro-forming process simulation.

• 한국정밀공학회지
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• 제16권9호
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• pp.41-47
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• 1999

The scale of dendritic structure of a cast preform plays a key role in determining the mechanical properties of cast/forged products. In this study, casting experiments are carried out to reduce dendrite arm spacing (DAS) to smaller than 20 ${\mu}$m by increasing cooling rate of the mold and then to spheriodize dendritic structures by addition of alloying elements such as Zr and Ti-B. From the casting experiments, appropriate casting conditions for producing the cast preform of a motorcycle connecting rod are obtained. To obtain fine microstructures of the cast preform, mold temperature must set to be low whilst cooling rate being high. When cooling rate is 10 $^{\circ}C$/s, the size of DAS is 17.4 ${\mu}$m. And the degree of spheriodization of a grain in the cast preform is described by aspect ratio, which is defined as the ratio of major and minor radii of an elliptical grain. When 0.5% Zr and 0.24 % Ti+B are added to the molten aluminum alloy, the best aspect-ratio 0.75 is obtained. After forging the cast preform of a motorcycle connecting rod, the microstructure and mechanical properties of the cast preform are compared with those of the cast/forged product. Cast/forged products are superior in microstructure and in mechanical properties such as ultimate strength, elongation, and hardness.

• 소성∙가공
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• 제19권1호
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• pp.25-31
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• 2010

To achieve desired microstructure and mechanical property of a manufacturing product, heat treatment process is applied as a secondary process after forging. Especially, quenching process is used for improving strength, hardness, and wear resistance since phase transformation occurs owing to rapid heat transfer from the surface of the specimen. In the present paper, a study on surface temperature measurement for water quenching of eutectoid steel was investigated. In order to determine the temperature history in experiments, three different measuring schemes were used by varying installation techniques of K-type thermocouples. Depending on the measured temperature distribution at the surface of the specimen, convective heat transfer coefficients were numerically determined as a function of temperature by the inverse finite element analysis considering the latent heat generation due to phase transformation. Based on the inversely determined convective heat transfer coefficient, temperature, phase, and hardness distributions in the specimen after water quenching were numerically predicted. By comparing the experimental and computational hardness distribution at three different locations in the specimen, the best temperature measuring scheme was determined. This work clearly demonstrates the effect of temperature measurement on the final mechanical property in terms of hardness distribution.