• Proceedings of the KSME Conference
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• 2008.11a
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• pp.1113-1118
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• 2008

In the hot forging process, The forging defects that are caused by metal were strain, temperate, and inclusion. In this paper, the computer simulation analyzed the effective plastic strain and temperature behaviors. The quantitative analyses which proposed the effective mold design of S/CAM shaft was executed. The parameters of forging shape that affected on the optimize conditions that was calculated with simple equation were investigated. it is expected that the developed analysis model and design technique would greatly contribute to the drum brake optimal design considering temperature affected and material behaviors. This development could save more than 20% of production cost and reduced failure rate to more than 30%. By improving the life span of mold from 15,000 to 25,000, financial difficulty of company imposed on a mold manufacture could be overcome.

• Journal of the Korean Society of Industry Convergence
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• v.2 no.2
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• pp.187-194
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• 1999

Closed-die forging of spline was analysed using the upper bound elemental technique, Two different forging methods, denoted here as side extrusion-forging and upset forging, were proposed, The kinematically admissible velocity fields for each of the forging methods, which could express trapezoidal, rectangular and serration tooth forms, were presented. Upper bounds to forging loads and deformed configurations were predicted using the velocity fields. Theoretical results were compared with experimental ones. Experiments with lead were carried out at room temperature where grease was used as a lubricant. The present investigation revealed that analytical forging loads were reduced by using the side extrusion-forging but the upset forging could improve configuration of the final forged splines.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.194-197
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• 2009

The TR forging is a kind of continuous grain flow forging. The preform of crank shaft for TR forging process was a round bar with a ring groove. In the first stage, the preform was partly heated by induction heating and then forged by vertical and horizontal force in sequence. In this study, the simulation process of induction heating was proposed to evaluate the temperature distribution of preform for TR forging. The equivalent circuit method was adopted to find coil current of the preform with a various dimensions and power levels. With these results, the coupled electromagnetic and transient thermal analysis for induction heating was performed to evaluate the temperature distribution at the preform of crank shaft during induction heating process. This FE analysis technique with equivalent circuit method was verified by comparing the analysis results with the experimental results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.23-26
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• 2003

This paper explains the die cooling method for improving tool life in the hot forging process. In continuous forming operation such as hot forging process, performed at high speeds, temperature increases of several hundred degrees may be involved. Die hardness was reduced due to thermal softening. Factor of die fracture are wear and plastic deformation of die due to hardness reduction by high temperature. Because die service life was reduced due to this phenomenon during hot forging, quantified data for optimal die cooling method is required. The new developed techniques for predicting tool life applied to estimate the production quantity for a spindle component and these techniques can be applied to improve the tool life in hot forging process

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.10a
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• pp.105-112
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• 1996

Aluminium alloy have been used extensively as forging materials for aircraft components due to their high specific strength and corrosion resistance. A large portions of these materials are used as airframe components consisted of various combination of such Rib-Web structure. But the problem of high forging pressure and defect which were caused by narrow Rib thickness prevented from the favorable developments and laboratory scaled trials. In this study, optimization of forging variables such as corner radius and temperature in Rib-Wed structure were established. The 2 mm of corner radius minimized the forging pressure to get the fixed Rib height, which well coincided with theoretical result according to Upper-Bound analysis. And optimum workpiece temperature was below 450$^{\circ}C$ in consideration of grain growth and forging defects by local melting.

• Transactions of Materials Processing
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• v.3 no.3
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• pp.271-281
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• 1994

Titanium-6242 $({\alpha}+{\beta})$ alloy has been used for aircraft engine components such as disks and blades, because it has an excellent strength/weight ratio at high temperatures. When this material is forged to manufacture disks, process parameters should be carefully designed to control strain and temperature distributions within the process windows by which desirable mechanical properties can be produced. In the present investigation, it was intended to design the process parameters for a conventional hot forging of this material by using a rigid-thermoviscoplastic finite element analysis technique. It was assumed that the process was performed by a screw press which is capable of maintaining a constant ram speed during loading. From the analysis results, it was found out that the initial temperature of the workpiece and the die shape were important parameters to control the forging process. In result, these parameters were properly designed for hot forging of a disk with specific dimensions.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.993-996
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• 2005

This paper is concerned with transfer process on hot forging of bearing hub. Workers on hot forging have difficulty in working by high temperature and weight workpiece. And In conventional got forging of bearing hub, the material wasted to the flash accounts approximately 10% of the original workpiece. It is need manufacture automation and reduce the cost of forged products. Surface treatment of die and lubricant are investigated from experiment and FE-simulation for analysis of forming simulation. In order to hot forging process design considered flash thickness and blocker geometry and initial temperature of die and billet. This transfer process gave comparatively good results compared with actual products.

• Transactions of the Korean Society of Automotive Engineers
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• v.14 no.1
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• pp.86-91
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• 2006

Magnesium alloys have been widely used for many structural components of automobiles and aircraft because of high specific strength and good castability in spite of hexgonal closed-packed crystal structure of pure magnesium. In this paper, FE analysis was executed about the formability of AZ3l magnesium alloy on press forging process. For this, the variation of sheet temperature, distribution of punch force and the effect of heat transfer and friction between punch and sheet on the forming characteristics during press forging of AZ31 has been analyzed by finite element analysis. In order to obtain temperature dependence of material characteristics, uniaxial tension tests at elevated temperature were done under temperature of $100^{\circ}C\~ 500^{\circ}C$.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.138-143
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• 2005

Finite Element analysis is widely applied to elevated temperature forging processes and shows a lot of information of plastic deformation such as strain, stress, defects, damages and temperature distributions. In highly elevated temperature deformation processes, temperature of material and tool have significant influence on tool life, deformation conditions and productivities. To predict temperature related properties accurately, adequate coefficients of not only contact heat transfer between material and dies but also convection heat transfer due to coolants are required. In most F.E analysis, too higher value of contact heat transfer coefficient is usually applied to get acceptable temperature distribution of tool. For contact heat transfer coefficients between die and workpiece, accurate values were evaluated with different pressure and lubricants conditions. But convection heat transfer coefficients have not been investigated for forging lubricants. In this research, convection heat transfer coefficients for cooling by emulsion lubricants are suggested by experiment and Inverse method. To verify acquired convection and contact heat transfer coefficients, tool temperature was measured for the comparison between measured tool temperature and analysis results. To increase analysis accuracy, repeated analysis scheme was applied till temperature of the tool got to be in the steady-state conditions. Verification of heat transfer coefficients both contact and convection heat transfer coefficients was proven with good accordance between measurement and analysis.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.22 no.1
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• pp.173-177
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• 2013

The purpose of this paper is to investigate the influences on mechanical properties of two-stroke cycle motor pistons manufactured by casting, conventional forging and powder forging, through the comparison of characteristics, merits and disadvantages of each forming technology. For each forming technology, the optimal process parameters were determined through the experiments for several conditions, and microstructure, hardness, tensile strength and elongation of pistons are compared and analyzed. In conventional forging process, material temperature was $460^{\circ}C$ and the die temperature was $210^{\circ}C$ for the Al 4032. The optimal condition was found as solution treatment under $520^{\circ}C$ for 5 hours, quenching with $23^{\circ}C$ water, and aging under $190^{\circ}C$ for 5 hours. In powder forging process, the proper composition of material was determined and optimal sintering conditions were examined. From the experiment, 1.5% of Si contents on the total weight, $580^{\circ}C$ of sintering temperature, and 25 minutes of sintering time were determined as the optimal process condition. For the optimal condition, the pistons had 76.4~78.3 [HRB] of hardness, and 500 [MPa] of tensile strength after T6 heat treatment.