• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.225-229
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• 2008

We present an intelligent forging simulator AFDEX. The intelligent forging simulator is determined by the adaptive and optimal mesh generation technique and many intelligent application-oriented special functions which minimize the user-intervention during forging simulation. Of course, the solution accuracy should be optimized in the intelligent simulation. We have developed AFDEX to meet the requirement on intelligent simulation. Its characteristics are introduced with the help of typical application examples.

• Proceedings of the Korea Society for Simulation Conference
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• 2001.10a
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• pp.274-279
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• 2001

This paper presented a virtual manufacturing simulation system by using Virtual Reality Modeling Language (VRML) and Finite Element Method(FEM). The system is to simulate forging operation. Stress distributions and deformation profiles as well as the operation of forging machine can be simulated and visualized in the web. Since the forging machine, user interface, and specimen were modeled by using Java and VRML, the forging machine and analysis results were browsed and integrated on the web that is interfaced to users through EAI to show the whole forging simulation. The developed system realized the working environment virtually so that education and experiment of forging process could be performed effectively even on the PC.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2008.05a
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• pp.263-266
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• 2008

We apply a closed die forging technology to a large crankshaft of which forging weight amounts to 850kg. 40ton counter-blow hammer forging machine is used. The forging process is optimized to reduce the forming load using finite element simulation. AFDEX 3D is used for forging simulation. The experiment is compared with finite element prediction and a good agreement is observed. The successful development of a large crankshaft by the closed die forging technology will contribute to opening a new area of closed-die forging application and to enhancing competitiveness of national machinery industries especially including ship part and power generation industries.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.4
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• pp.47-54
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• 2013

The main cause of die failure in hot forging is wear. Die wear directly generates the gradual loss of part tolerances, thereby causing deterioration in the dimensional accuracy of a forged part. It is very important to estimate forging cycles, called as die life, at which the die should be repaired or replaced. In this study, in order to estimate the hot forging die life, the finite element simulation of wear on an asymmetric part like a ball joint socket used in vehicle was carried out based on Archard's model. Finite element simulation results were compared with wear amounts of a used die that were measured using a contact stylus profilometer. The simulation results were in relatively good agreement with measurements obtained from the virtual die which was used by 7,000 forging cycles in a forging industry. Consequently, the die life in the hot forging of the ball joint socket was estimated by 10,500 forging cycles on the finisher die.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.90-93
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• 1999

In this paper a local remeshing technique assisted by user-interface capabiities is presented for precise forging simulation. The rigid-plastic finite element formulation is introduced and the basic approach to the new local remeshing technique is presented. A piercing process in cold forging is simulated by the presented technique and the results are compared in detail.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.1
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• pp.32-39
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• 2004

Traditional forging of a hollow T-shaped part has been applied to forge a solid T-shaped product from a solid billet and then to machine the hollow in that. In a case, a hollow T-shaped part can be forged by backward-extruding from a solid billet. In this study, four types of forging were suggested for manufacture of hollow T-shaped parts. Forging simulations for each of these forging methods were carried out to investigate folding defect, metal flow pattern, effective strain, and forging loads. Experimental works were carried out to be compared with the simulation results. Here, the ratio of the thickness of the hollow tube to that of the flange was selected to investigate a forging defect like folding.

• Transactions of Materials Processing
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• v.19 no.7
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• pp.399-404
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• 2010

We propose an analysis model for simulating the detailed procedure of pore closing in open die forging of shafts. In the analysis model, an artificial symmetric plane is used, on which initial pores are located to be traced. The analysis model is employed to carry out three-dimensional simulation of pore closing in shaft free forging by both conventional free forging press and radial forging machine. With this result, two typical types of free forging equipment for manufacture of shafts are compared in detail. It has shown that the radial forging machine is much superior to the conventional open die forging press especially in pore closing under high hydrostatic pressure with sound strain.

• Transactions of Materials Processing
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• v.28 no.2
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• pp.98-104
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• 2019

The present study numerically simulates the deformation heterogeneity developed in AA1100 during multi-axial diagonal forging (MADF) using finite element analysis (FEA). Diagonal forging type consisting of diagonal forging (DF) and return-diagonal forging (R-DF) proved to be relatively beneficial compared to plane forging type which includes plane forging (PF) and return-plane forging (R-PF) for minimizing the non-uniformity of deformation developed in workpieces. Simulation of the effective strain generated in workpieces during the two types of forging was done using 3-D FEA. FEA shows the effect of friction coefficient on the deformation behavior on workpieces. The simulation of 2 types forging with different friction coefficients revealed that the magnitude of barreling effect and strain heterogeneity in workpieces increases with an increase in the friction coefficient.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.165-169
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• 2007

In this study, the factors that have strong relationship with size effects on forging simulation are investigated and then a dimensionless concept is implemented into the forging simulator. The approach is applied to simulating a micro former forging process of which sequence involves a piercing process to make a hole of 0.7mm diameter of the product whose maximum diameter is 3mm. The simulated results are discussed to reveal the size effect in forging simulation.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.10
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• pp.180-185
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• 2000

In this paper, a local remeshing technique assisted by flexible user-interface capabilities is presented for precise forging simulation. The rigid-plastic finite element formulation is introduced and the detailed approach to the new local remeshing technique is given. A piercing process in cold forging is simulated by the presented technique and the simulated results are compared with those obtained by the technique and the simulated results are compared with those obtained by the conventional approach and experiments. A typical application example is also given, which emphasizes the capability of the local remeshing technique in forging simulation.