• Journal of the Korean Society for Precision Engineering
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• v.22 no.11 s.176
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• pp.45-50
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• 2005

In this study, the casting/forging process was applied in manufacturing a low control arm, in order to prove that application of casting/forging process to Al6061 is likely to get the effect of light weight compared with existing steel products and to reduce the cost of materials. Firstly, In order to set up the optimum casting condition of the forging material, Al6061, casting experiments were carried out by controlling pouring temperature of the aluminum for casting, mold temperature, and pouring time. $700^{\circ}C$ pouring temperature, $300^{\circ}C$ mold temperature and 10-second pouring time were taken into account as the optimum casting conditions. With respect to a hot forging test, it is practiced on the basis of a temperature of materials, strain rate, and reduction rate so as to observe each microstructure and examine strain-stress curve simultaneously; examine tensile test and hardness test; eventually set up the optimum hot forging condition. A hot forging test, tensile test, hardness experiment, and microstructure observation were carried out on condition of $70\%$ reduction rate, $500^{\circ}C$ temperature of materials, and 1 strain rate. As a result of those experiments, 330MPa tensile strength, $16.4\%$ elongation, and 122.8Hv hardness were recorded. In oder to get a sound preform which has no unfitting cavity and less flash, two preforms were proposed on the basis of volume rate of the final product; the optimum volume rate of preform for the low control arm was $115\%$. In conclusion, it is confirmed that using the forging material rather than casting materials in casting/forging process is likely to get more superior mechanical properties. Compared with Al6061, performed by means of general forging, moreover, cast/forged Al6061 can not only stimulate productivity by reducing production processes, but cut down the cost of materials by reusing forging scraps.

• 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.

• Transactions of Materials Processing
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• v.4 no.1
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• pp.9-16
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• 1995

Model material technique, which requires only the small space of experimental set-up and low cost for experiment, is used to estimate the deformed profile and the forging load in rotary forging. The materials and working conditions are determined to satisfy the similitude conditions between the model test and the prototype test. The model material of the so-called plasticine and the mild steel are chosen as specimens, and they represent almost the same value of strain gardening exponent in the stress-strain relationship. Lubricant in the model test is also carefully selected so that it gives the same frictional conditions at the tool-specimen interface. Experiments for two kinds of specimens are carried out in each testing equipment at room temperatue. From the experiments the deformed dimensions and the forging loads are measured and compared with each other by using the simulation coefficients. It is shown that there are good agreements between the model test and the prototype test. Finally, for verifying the availability of the model material technique this mathod is applied to forging of bevel gear product. the good result is obained which can demonstrate that the model material technique is very efficent for estimating or developing a new process.

• Journal of Powder Materials
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• v.4 no.4
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• pp.258-267
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• 1997

The powder forging process is an attractive manufacturing route for bevel gears. It offers beneficial material utilization and the minimization of finishing operations over that of conventional hot forging. The paper describes the process conditions for the powder forging of bevel gear, for example, powder alloy design, preform design, deformation of sintered preform, forging processes. The characteristics of prototype gear are investigated with microstructure, the density distribution, surface roughness of tooth, bending strength test of tooth, etc. The results of the bending strength test may prove the mechanical properties of powder forged gear.

• Transactions of Materials Processing
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• v.27 no.6
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• pp.370-378
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• 2018

Cold forging, carried out at room temperature, leads to high dimensional accuracy and excellent surface integrity as compared to other forging methods such as warm and hot forgings. In the cold forging process, WC-Co (Tungsten Carbide-Cobalt) alloy is the mainly used material as a core dies because of its superior hardness and strength as compared to other structural materials. For cold forging, die life is the most significant factor because it is directly related to the manufacturing cost due to periodic die replacement in mass production. To investigate die life of WC-Co alloy for cold forging, mechanical properties such as strength and fatigue are essentially necessary. Generally, uniaxial tensile test and fatigue test are the most efficient and simplest testing method. However, uniaxial tension is not efficiently application to WC-Co alloy because of its sensitivity to alignment of the specimen due to its brittleness and difficulty in thread machining. In this study, shape of specimen, tools, and testing methods, which are appropriate for uniaxial tensile test for WC-Co alloy, are proposed. The test results such as Young's modulus, tensile strength and stress-strain curves are compared to those in previous literature to validate the proposed testing methods. Based on the validation of test results it was concluded that the newly developed testing method is applicable to other cemented carbides like Titanium carbides with high strength and brittleness, and also can be utilized to carry out fatigue tests for further investigation on die life of cold forging.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.10a
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• pp.244-247
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• 2001

Lubricanting characteristics in the warm forging have influence on forgeability of products. but Research on deformation characteristic of warm forging on the lubricant and lubricating method lack. This paper deform a bevel gear by warm forging and evaluate deformation loads and quality of products by each lubricants and lubricating method using oil-based lubricants(Soy, Oildag) and water-based lubricants(Deltaforge $\#31$, Renite S-26-X, Deltaglaze $\#151$). In conclusion, the less a deformation load by lubricants the more improvement a quality of product in manufacture of a bevel gear and water-based lubricants in the warm forging reduce a deformation load and improve a quality of products. Especially, Deltaforge $\31$ have excellent characteristic in the warm forging.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06b
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• pp.43-53
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• 1998

Heat - affected zones degenerated in cold forging die have been investigated to improve the tool life. There are many cases of heat-affected zone which are degenerated in manufacturing die and using the cold forging process. In order to define amounts of grinding inmanufacturing the toolfor cold forging, we have investigated the hardness and microstructure of surface layer after EDM. Considering the results of T.R.S. and compression test, it is likely that mechanical properties of tool have been decreased sharply if the heat-affected zones degenerated by EDM were not machined properly. also analyzed the tool surfac which is fractured during the cold forging. According to the microstructures and hardness distribution, surface of many tools have been degenerated in cold forging and fractured due to the heat-affected zone.

• Transactions of Materials Processing
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• v.14 no.7 s.79
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• pp.619-623
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• 2005

Lubrication and cooling characteristics are the most important factors of elevated temperature forging lubricants. Usually adopted lubricants in warm forging processes are graphite, synthetic and emulsion lubricants. Most widely and effectively applied lubricants are graphite lubricants, but these have a lot of problems like tool corrosion and dusty environment. In this research, boronite lubricant is considered, because it is able to substitute for graphite. Hot ring compression test, cooling test and mass production test are performed to check the validity of new lubrication pigment.

• Transactions of Materials Processing
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• v.6 no.3
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• pp.227-232
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• 1997

This study is concerned with the rotary powder compacting by the cold rotary forging process. An experiment has been carried out using the rotary powder forging press(500kN) which was designed and constructed in the authors' laboratory. The detailed comparisons of several mechanical test by rotary powder forging and rotary powder compacting process are given. It is found that the highly densified P/M parts can be obtained and this process is very effective for improving quality of the powder products.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.10a
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• pp.370-373
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• 2008

Small size gas turbine disk requires good mechanical strength and creep properties at high temperature. In this study, Waspaloy was used as a superalloy to satisfy these specifications. The control of microstructure was needed to satisfy material properties at high temperature. In order to do this, we studied forging conditions and material analysis. Therefore die and preform design conducted so that hot forged gas turbine disk could have a good microstructure. The die and preform shapes are designed with consideration of the predefined hydraulic press capacity and the microstructure of forging product. Also we carried out the hot compression test for Waspaloy in various test conditions. From these results, we obtained the forging conditions as material temperature, die velocity etc. To verify these forging conditions, we conducted FE simulations by means of the DEFORM 2D-HT. In this study, the hot closed die and preform designs were completed to offer high temperature material properties of a small size gas turbine.