• 소성∙가공
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• 제28권5호
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• pp.257-265
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• 2019

Multi-axial forging (MAF), a severe plastic deformation technique, is known to be difficult to obtain materials with homogeneous microstructures. Recently, multi-axial diagonal forging (MADF) process has been developed to solve this problem. In this study, in order to compare the microstructural and mechanical homogeneities of the MAFed and MADFed samples, oxygen-free copper (OFC) cubes measuring 25 mm in length were deformed through MAF and MADF processes and the average grain size and hardness were measured at the edge, face, and center regions of the samples. In the MAFed samples, ultrafine grains were formed at the center region, but a considerable amount of coarse grains remain at the face region. Therefore, the MAFed samples showed a high inhomogeneity in regards to grain size and hardness. On the contrary, in the case of the MADFed sample, the grain sizes at the edge, face, and center regions were similar and the hardness in all the regions are almost similar. This indicates that the MADFed sample has a homogeneous microstructure and uniform mechanical properties, which can be attributed to the homogeneous distribution of the effective strain throughout the material. The results of this study suggests that the MADF is a suitable process in the fabrication of high-strength copper materials with a homogeneous and ultrafine grain structure.

• 대한기계학회논문집
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• 제18권9호
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• pp.2234-2244
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• 1994

A process sequence of multi-operation cold forging for actual application in industry is designed with the rigid-plastic finite element method to form a constant velocity joint housing(CVJ housing). The material flow during the CVJ housing forming is axisymmetric until the final forging process for forming of ball grooves. This study treats the deformation as an axisymmetric case. The main objective of the process sequence design is to obtain preforms which satisfy the design criteria of near-net-shape product requiring less machining after forming. The process sequence design also investigates velocity distributions, effective strain distributions and forging loads, which are useful information in the real process design.

• 한국공작기계학회논문집
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• 제16권4호
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• pp.29-35
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• 2007

The main objective of this paper is to propose the optimal design method of forging process using genetic algorithm. Design optimization of forging process was doing about one stage and multi stage. The objective function is considered the filling of die. The chosen design variables are die geometry in multi stage and initial billet shape in one stage. We performed FE analysis to simulated forging process. The optimized preform and initial billet shape was obtained by genetic algorithm and FE analysis. To show the efficiency of GA method in forging problem are solved and compared with published results.

• 한국생산제조학회지
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• 제19권1호
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• pp.33-41
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• 2010

This study was aimed at the design of the dies for the unified pipe joint of the intermediate shaft using the computer simulation to shorten the period of production, on the basis of the process planning which was designed by the field experts. In the computer simulation, 'Deform-3d' and 'eesy-DieOpt' have been used, which are the commercial process analysis and die design program. Through the process analysis, we could know the propriety of the forming process, the inner pressure of the die and the suitable fitting pressure between the insert and the sleeve which was not showing any positive tangential stresses in the insert. Through the simulation of die design, we could know the number of the stress ring, the diameter ratios, the stresses of the die, the shrink fitting tolerance and temperature in the condition of the already determined maximum outer die diameter of the multi-stage former. The validity of the die design using the computer simulation was analyzed by the experiments and the results were satisfactory. As the results of this study, the new and easy die design system for multi-forging has been developed.

• 한국기계가공학회지
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• 제21권1호
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• pp.49-55
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• 2022

Recently, the automobile industry has continued to demand lighter materials owing to international environmental regulations and increased convenience. To address this demand, aluminum parts have increased in popularity and are mainly developed and produced through hot forging and cold pressing. However, because this method has low yield and low production efficiency, a new manufacturing method is desirable. In this study, the water capacity efficiency of an aluminum inner tie rod socket was investigated using cold forging that provided a high yield and excellent production efficiency. Mechanical properties were derived through tensile testing of 6110A aluminum materials, and critical fracture factor and process analysis based on experimental data were carried out. The optimized process was applied as a prototype using cold multi-stage forging, and based on the derived results, the formability, productivity, and material efficiency of aluminum inner tie rod socket parts using this cold forging process was verified.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1995년도 추계학술대회논문집
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• pp.30-36
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• 1995

Conventionally design for multi-stage cold forging depends on the designer's experience and decision-making. Due to such non-deterministic nature of the process sequence design, a flexible inference engine is needed for process design expert system. In this study, A* searching algorithm was introduced to arrive at the vetter process sequence design considering the number of forming stages and levels of effective strain, effective stress, and forming load during the porcess. In order to optimize the process sequence in producing the final part, cost function was defined and minimized using the proposed A* searching algorithm. For verification of the designed forming sequences, forming experiments and finite element analyses were carried out in the present investigation. The developed expert system using A* searching algorithm can produce a flexible design system based on changes in the number of forming stages and weights.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 춘계학술대회 논문집
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• pp.317-320
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• 2005

The micro-alloying forging steels have been developed to save energy consumption during forging and subsequent heat treatment stages. The work hardening ability of micro-alloying forging steels is one of major hardening component while it gives severe die damage if the forging process design is poorly set up on the other hand. In the present study, it was tried to characterize three types of micro-alloying forging steels to understand the differences with the conventional low carbon steels used fur cold forging with a spherodizing heat treatment. After forging of a certain forging part with both micro-alloying forging steels and conventional low carbon steel, several mechanical tests were carried out.

• 한국기계가공학회지
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• 제17권4호
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• pp.83-90
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• 2018

In this research, we developed a process design hot-forging technology that precisely forms an inner race. The inner race transmits power to a one-way clutch of an automatic transmission and minimizes the CNC machining allowance. For a multi-stage hollow shape (inner race), we proposed several shapes of blocker and finisher for the precision hot-forging process and analyzed the forging process using DEFORM. The hot-forging process was optimized for several parameters, such as metal flow pattern, forging defect, and forming load. Blockers and finisher dies in the hot-forging process were designed to select optimal shapes from finite element analysis, and experiments were conducted to optimize the hot-forging process.

• 소성∙가공
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• 제30권4호
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• pp.172-178
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• 2021

The cold forging process induces material deformation in an enclosed space, generating a very high forging load. Therefore, it is mainly designed as a multi-stage process, and fatigue failure occurs in forging die due to cyclic load. Studies have been conducted previously to quantitatively predict the fatigue limit of cold forging dies, however, there was a limit to field application due to the large error range and the need for expert intervention. To solve this problem, we conducted a study on the introduction of a real-time forging load measurement technology and an automated system for quantitative prediction of die life cycle. As a result, it was possible to reduce the error range of the quantitative prediction of die life cycle to within ±7%, and it became possible to use the die life cycle calculation algorithm into an automated system.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2006년도 춘계학술대회 논문집
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• pp.399-402
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• 2006

The outer race of CV(constant velocity) joint is an important load-supporting automotive part, which transmits torque between the transmission gear box and driving wheel. The outer race is difficult to forge because its shape is very complicated and the required dimensional tolerances are very small. Traditional warm and cold forging methods have their own limitations to produce such a complex shaped part; warm forging requires complex system with relatively higher manufacturing cost, while cold forging is not applicable to materials with limited formability. Therefore, multistage forging may be advantageous to produce complex shaped parts. In order to build a multistage forging system, it is necessary to characterize mechanical properties in response to system design parameters such as temperature, forging speed and reduction. For the analysis of formability of multistage forging process, finite element method(FEM) has been used for the process analysis. As a model case, a constant velocity (CV) joint forging process is analyzed by FEM, since CV joint has a complex shape and also its required dimensional tolerances are very tight. The data acquired by FEM is compared with operational forging data obtained from an industrial production line. Based on this comparative analysis, multistage forging process for CV joints is proposed.