• Journal of the Korean Society for Precision Engineering
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• v.13 no.11
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• pp.106-113
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• 1996

Using stainless steel as the cold forged parts especially the outer parts of automobile is gradually increasing because it can bear up against the erosion and the wear. During cold forging of the stainless steel the working pressure acting on die surface are very high therefore the wear on die surface can be greatly increased. In cold forging processes, die failure must be considered before die design. One of the main reasons of die failure in industrial application of metal forming technologies is wear. The die wear affects the tolerances of forged parts, metal flow and costs of processes etc. The only way to to control these failures is to develop methods which allow prediction of the die wear and which are suited to be used in the desing stage in order to optimize the process. In this paper, the rigid-plastic finite element method was combined with the wear prediction routine and then the forward extrusion process using stainless steel was analysed simultaneously. To minimize the die wear the FPS algorithm was applied and the optimal conditions of die configuration are suggested.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.9
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• pp.45-51
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• 1997

For semi-solid forging, it is necessarily required to prepare a workpiece with globular microstructure. Among several processes to obtain golbular microstructure, SIMA process is very simple and advantageous with respect to equipment. This paper presents the influence of effective strain on the globularization with aluminium 2024 alloy in cold working stage by SIMA process. Upsetting and forward extrusion are tested for cold working and induction heating is also carried out for reheating to obtain golbular microstructure. Microstructure is observed with an optical microscope. And finite element simulations to obtain effective strain in cold working stage are performed by using commercial finite element code, DEFORM.

• Journal of Advanced Marine Engineering and Technology
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• v.33 no.1
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• pp.97-103
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• 2009

The process design of forward Extrusion and Upsetting of Axi-symmetric part has been studied in this paper. During the cold forging product; auto transmission Solenoid Valve part, the defects such as folding and under-fill can be appeared by the improperly controlled metal flow. In this study, to reduce the folding and under-fill the design of experiments has been used to find out the significant design variables in the design of forging process. This paper deals with an Process Planning with which designer can determine operation sequences even after only a little experience in Process Planning of Multi-Former products by multi-stage former working. The approach is based on knowledge-based rules, and a process knowledge-base consisting of design rules is built. Based on the systematic procedure of process sequence design, the forming operation of cold forged auto transmission Solenoid Valve part is analyzed by the commercial Finite Element program, DEFORM/2D.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.40-42
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• 2003

The aim of this paper is to illustrate which factors influence the martensite grain fineness made by subsequently surface carburizing of extruded component. The effects of surface decarburizing by annealing, residual stress, initial microstructure and crystal oriental made by forward extrusion were taken into account. The available evidence suggests that the residual stress inside crystal or the crystal orientation is the main factor that results coarse martensite while cold extruded component was treated by carburizing.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.9
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• pp.165-173
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• 1996

The dimensional accuracy of a final product is mainly affected by elastic die deformation during the forging and elastic recovery after the ejection in cold forging process. The investigations on elastic recovery are not so much as those of elastic die deformation. The elastic recovery can be determined by using the elastic-plalstic finite element analysis, but, this method has some limits such as poor conver- gence and long computational time, etc. In this paper, a theoretical analysis for predicting the elastic recovery of a final product in axi-symmetric forging process by using the rigid-plastic finite element method is presented. The rigid-plastic finite element analysis of a cold forward extrusion process involving loading, ejecting process is accomplished by rigid-plastic FE code, DEFORM. The effect of elastic die deformation on the final product dimenmsion is also considered. The calculated elastic recovery is compared is compared with the analysis result of elastic-plastic FE code. ABAQUS.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.04a
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• pp.155-158
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• 2000

Flow defect of a piston-pin for automobile parts is investigated in this study. In cold forging of piston-pin Lapping defect a kind of flow defect appears by the dead metal zone. This appearance evidently happens in products with a thin piercing thickness for the dimension accuracy and the decrease of material loss. The best method that can prevent flow defect is removing dead metal zone. The finite element simulations are applied to analyze the flow defect. This study proposed processes for preventing flow defect by removing dead metal zone. Then the results are compared with the experiments for verification. These FE simulation results are in good agreement with the experimental ones.

• Transactions of Materials Processing
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• v.18 no.6
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• pp.453-457
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• 2009

In this paper, plastic deformation behaviors of ESW105 and SCM435 steels are revealed by simulations and experiments. ESW105 is the special pre-heat-treated steel characterized by high initial yield strength and negligible strain-hardening behavior. The flow stresses of the two steels for large stain are calculated from tensile tests. Axial and lateral compressions of cylindrical bars are tested and simulated and the deformed shapes are compared to characterize the plastic deformation behaviors of the two materials. A forward extrusion process of a cylindrical bar is also simulated to reveal the difference. It has been shown that there are pretty much difference in plastic flow between ESW105 and SCM435 which causes from the difference in strain-hardening capability, implying that the experience-oriented design rules for common commercial materials may lead to failure in process design when the new material of ESW105 is applied without consideration of its plastic deformation behavior.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.48-51
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• 2009

In this paper, plastic deformation behaviors of ESW105 and SCM435 steels are revealed by simulations and experiments. ESW105 is the special pre-heat-treated steel characterized by high initial yield strength and negligible strain-hardening behavior. The flow stresses of the two steels for large stain are calculated from tensile tests. Axial and lateral compressions of cylindrical bars are tested and simulated and the deformed shapes are compared to characterize the plastic deformation behaviors of the two materials. A forward extrusion process of a cylindrical bar is also simulated to reveal the difference. It has been shown that there are pretty much difference in plastic flow between ESW105 and SCM435 which causes from the difference in strain-hardening capability, implying that the experience-oriented design rules for common commercial materials may lead to failure in process design when the new material of ESW105 is applied without consideration of its plastic deformation behavior.