• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10b
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• pp.127-132
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• 2003

This article mainly introduces the research of closed forging on 20MN hot die forging presses. After transforming of the equipments, optimizing of die design and improving of die-manufacturing precision, gear blanks used in car gearbox have been forged out without fins successfully.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.12
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• pp.2970-2981
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• 1993

In hot closed-die forging the load increases rapidly near the final stage. Preforming operation is important to both the sound final forging and die-service life. In this study, the material flows during preforming and final forging are investigated. The physical modeling with Plasticine as a model material showed clear flow patterns. The forging process were numerically simulated by the finite element method with the isothermal and the non-isothermal models. The flow patten of the isothermal simulation showed good agreements with the experiments. Temperature changes and pressure distributions on the die surfaces during one cycle of the forging process were obtained from the non-isothermal simulation. High pressure and temperature were developed at certain areas of the die surfaces. It was concluded that those areas usually coincide with each other and should be distributed by the preforming operations to enhance the die life.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.199-203
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• 2003

Idler of excavator are large product with diameter 500 - 600 mm and parts of a power transmit device. The object of the paper is developed large products by hot closed-die forging. The forging process which is proposed from numerical analysis and various tests is developed a large products with good quality. To estimate the design process parameters such as working load, temperature and flash thickness so on, numerical analysis are used by DEFORM 2D. To obtain a flow stress data and optimal forging temperature is carried out hot compression and tensile test at a various temperature range. Developed product is tested mechanical properties of elongation, hardness and tensile strength so on. Test results are presented excellent mechanical properties.

• 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.

• Design & Manufacturing
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• v.15 no.1
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• pp.14-20
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• 2021

The objective of this study is to introduce the new possibility of sensing technology based on inductive displacement sensors to monitor the status of wheel position in the hot forging process. In order to validate effectiveness of proposed sensing technology, the indirect forging force measurement with displacement sensor was applied into a typical closed hot forging die-set used for the manufacturing of flange bolts. The locations to implement the displacement sensor were selected carefully by simulating forming process and static structural. From the measurement results of the forging force change during one hot forging cycle, it was found that the proposed monitoring system can provide useful information to understand the detailed behaviors of die-set in the closed hot forging process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2003.06a
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• pp.1513-1516
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• 2003

A crank throw, which is one of the crankshaft part for a large diesel engine is manufactured by closed die forging or open die forging. For the purpose of improvement of productivity the open die forging is usually adopted these days. However it has disadvantage of low yield ratio compare to closed die forging. To overcome this problem, the material properties for hot top and bottom zones of ingot are investigated to utilize them to the product and a modified forging process to reduce the material loss of ingot body through forging analysis according to forging factors(a , R, Ø$\sub$B/, Ø$\sub$D/) is suggested.

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.627-632
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• 2001

Nimonic 80A superalloy with high-temperature strength and high corrosion-resistance is used in jet engine for aircraft, gas turbine for power plant and marine diesel engine, etc. To develop the manufacturing process of exhaust valve for large diesel engine using Nimonic 80A, various mechanical tests, such as hot compression, microstructure and hardness test have been performed. This results effectively used to set the reasonable forging conditions while hot forging of Nimonic 80A superalloy. Open die and closed die forging experiments are carried out from ESR ingot and finally get a good shaped exhaust valve product.

• 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.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.126-129
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• 1998

Proper design of blocker dies is one of the most important aspect of impression and closed-die forging to achieve adequate metal distribution. Determination of the blocker configuration is a very difficult task and is art in itself, requiring skills achieved only by years of extensive experience. To save the cost and time of blocker design, many methods using computer were proposed. In this research, low pass filter method proposed by Oh etc. was applied to blocker die design of spoiler support, part of aircraft and plasticine model experiment of closed die forging of spoiler support was accomplished to verify the validity of the blocker designed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.8
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• pp.2458-2467
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• 1996

The rigid-plastic finite element analysis was performed for analysis of ofhot forging and cold sizing of a bevel gear. Two dimensional analysis was carried out to investigate the defect occurrence on vertical symmetric planes during hot forging and three dimensional analysis was to understand the filling behavior on horizontal planes during cold sizing. The involute curve of a tooth was approximated by a circle for convenience in the present analysis. In order to estimate the elastic deformation of the gear and dies during cold sizing, linear elastic finite element analysis was performed. Results of the analysis can be used to predict grain flows and strength distributions in the forged gear, and to design dies and an appropriate preform for the cold sizing.