• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.04a
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• pp.85-91
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• 2002

Of all the many types of machine elements which exist today, gears are among the most commonly used. Many researches have been done to manufacture helical gears by cold forging and extrusion. Although cold forging and extrusion were applied to some bevel, spur, and helical gears, problems in connection with reducing forming load and tool life still make it difficult for the related methods to be commercialized. In this study, focusing on reducing load in forming helical gears, extrusion of helical gears by a two-step process is proposed. The process is composed of an extrusion step of spur gears used as preform and a torsion step of the preform to make helical gears. Upper-bound analysis for the two-step process is performed and compared with results of experiments. The newly proposed method can be used as an advanced forming technique to remarkably reduce the forming load and replace the conventional forming process of helical gears.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.824-828
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• 2002

Of all the many types of machine elements which exist today, gears are among the most commonly used. Many researches have been done to manufacture helical gears by cold forging and extrusion. Although cold forging and extrusion were applied to some bevel, spur, and helical gears, problems in connection with reducing forming load and tool life still make it difficult for the related methods to be commercialized. In this study, focusing on reducing load in forming helical gears, extrusion of helical gears by a two-step process is proposed. The process is composed of an extrusion step of spur gears used as preform and a torsion step of the preform to make helical gears. Upper-bound analysis for the two-step process is performed and compared with results of experiments. The newly proposed method can be used as an advanced forming technique to remarkably reduce the forming load and replace the conventional forming process of helical gears.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.05a
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• pp.170-173
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• 2004

Recently many kinds of gears have been produced by forging in order to enhance the mechanical properties of the gears and the productivity of the process. Developments in forging technology are the reason for the increased usage. However, a critical problem of the forged gears is the dimensional change or distortion caused by elastic recovery after forging, and relief of the residual stresses during subsequent heat treatments. Distortion is of great concern to the manufacturers of precision parts, because it influences directly the dimensional accuracy and the grade of carburized bevel gears. In the present paper, distortion due to elastic and heat treatment of bevel gears Is investigated. Distortions of forged gears, machined gears and die aremeasured and compared. Numerical analysis is used to simulate the complete cold forged process and heat treatment process for the machined gears and shows good agreement with the experimental measurements.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.6
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• pp.142-151
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• 2013

This study develops an automation system for metallic mold design that is applicable in forging non-axial symmetric parts. The metallic mold design program is used to design the metallic mold using two-dimensional axial symmetric metallic molds and to predict the stress concentration using finite element analyses. Then, the program redesigns the metallic mold using variables such as the optimal split diameter, maximum allowable inner pressure, fit tolerance, and stress distribution, which are calculated using the metallic mold design program. When the involute spur gear is forged, stress concentration occurs on the tooth root bounded at the symmetric surface. The SCM4 material is suitable for metallic molds because the stress is less than the yield strength of the insert and it acts on the tooth root regardless of the inner pressure. The metallic mold for forging non-axial symmetric parts can be designed through adjusting the magnitude of the contact pressure. The program developed in this study can be applied to metallic mold designs in involute spur gears of forging, which is an ordinary non-axial symmetric part.

• Transactions of Materials Processing
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• v.23 no.2
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• pp.95-102
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• 2014

The under-drive brake piston is an important component in automotive transmissions. It changes the velocity by controlling the gear ratio. It has been traditionally manufactured by hot forging. Recently, there has been an effort to replace this traditional manufacturing method with cold forging in order to improve the dimensional accuracy and decrease the surface roughness. Cold forging uses a smaller amount of initial material and also has a shorter cycle time since the forged surface can be the final surface without the need of post-processing such as machining or grinding. In the current study, finite element analysis was conducted to evaluate a process design using an initial plate with reduced thickness. This smaller thickness decreases the amount of material needed for the part as well as the machining to produce the final product.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.42-47
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• 2007

The characteristics of the tool system give many effects into the costs and qualities for the finished components. Therefore, a tool life is one of the important issues on cold forging industry. However, since variables related with tool life are many complicated, the studies for solution should be investigated by the systematic research approach. The shape and process changes of die, the hardness changes of material and the tolerance of dies to decrease the die stress are analyzed by the FEM software. The heat-treatment of tool material is investigated to improve the tool life. Deep cryogenic treatment of tool steel is very efficient to improve the wear resistance due to the fine carbide. And, it is investigated that the shape and dimension of tool give effect into both tool life and quality of forged product..

• Transactions of the Korean Society of Mechanical Engineers A
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• v.40 no.2
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• pp.221-227
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• 2016

The main shaft is one of the key components connecting the rotor hub and gear box of a wind power generator. Typically, main shafts are manufactured by open die forging method. However, the main shaft for large MW class wind generators is designed to be hollow in order to reduce the weight. Additionally, the main shafts are manufactured by a casting process. This study aims to develop a manufacturing process for hollow main shafts by the open die forging method. The design of a forging process for a solid main shaft and hollow shaft was prepared by an open die forging process design scheme. Finite element analyses were performed to obtain the flow stress by a hot compression test at different temperature and strain rates. The control parameters of each forging process, such as temperature and effective strain, were obtained and compared to predict the suitability of the hollow main shaft forging process. Finally, high productivity reflecting material utilization ratio, internal quality, shape, and dimension was verified by the prototypes manufactured by the proposed forging process for hollow main shafts.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1994.06a
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• pp.69-78
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• 1994

A rotating disk is introduced to be applied to the deep drawing press. Several characteristics are summarized to see the basics of deep drawing of sheet metal in terms of load-stroke relationship and formability. Many conventional drawing presses, which are mostly link-type presses, are also shown to be compared with the rotating disk-type press. Performances of the new press are kinematically analyzed it terms of load-main gear angle relationship, stroke-gear angle relationship, and slide velocity-gear angle relationship and they are compared with those of conventional types', e. g. crank press and so on. The comparison show kinematically better performance of rotating disk-type press than that of conventional ones. Also, the new press are proven to be one of the best press for mass production in terms of cycle time. Applicability of the rotating disk press to deep drawing and cold forging work is introduced. The new press is described in terms of economy such that the cost of new press would be much lower than those of conventional types'.

• Transactions of Materials Processing
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• v.21 no.4
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• pp.234-239
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• 2012

This study examines the forming properties and forming loads needed to increase the edge thickness on the external face of a plate using finite element analysis(FEA). Recently, forming optimization techniques within FEA are being extensively used in designing the optimal forming conditions for processes like forging, extrusion, rolling, and spinning. Most of these existing forming operations involve reducing the volume per unit length, but research for increasing volume per unit length is not very extensive. For this study we chose an automotive engine flywheel which is a welded assembly of a plate and a gear with each component having a different thickness. We considered a forming technique to increase the thickness in order to allow the machining of the gear directly on the external face of plate alleviating the need for a weld. To study various forming techniques, we used the finite element method with the flow stress of material and incremental forming steps. We conclude from this study that the analysis of forming properties and forming loads by using the finite element analysis and testing is useful as a method to increase the thickness per unit length.

• Journal of Computational Design and Engineering
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• v.1 no.1
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• pp.27-36
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• 2014

Similar to the essential components of many mechanical systems, the geometrical properties of the teeth of spiral bevel gears greatly influence the kinematic and dynamic behaviors of mechanical systems. Logarithmic spiral bevel gears show a unique advantage in transmission due to their constant spiral angle property. However, a mathematical model suitable for accurate digital modeling, differential geometrical characteristics, and related contact analysis methods for tooth surfaces have not been deeply investigated, since such gears are not convenient in traditional cutting manufacturing in the gear industry. Accurate mathematical modeling of the tooth surface geometry for logarithmic spiral bevel gears is developed in this study, based on the basic gearing kinematics and spherical involute geometry along with the tangent planes geometry; actually, the tooth surface is a parametric surface defined on a parallelogrammic domain. Equivalence proof of the tooth surface geometry is then given in order to greatly simplify the mathematical model. As major factors affecting the lubrication, surface fatigue, contact stress, wear, and manufacturability of gear teeth, the differential geometrical characteristics of the tooth surface are summarized using classical fundamental forms. By using the geometrical properties mentioned, manufacturability (and its limitation in logarithmic spiral bevel gears) is analyzed using precision forging and multiaxis freeform milling, rather than classical cradle-type machine tool based milling or hobbing. Geometry and manufacturability analysis results show that logarithmic spiral gears have many application advantages, but many urgent issues such as contact tooth analysis for precision plastic forming and multiaxis freeform milling also need to be solved in a further study.