• 한국기계가공학회지
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• 제19권9호
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• pp.93-99
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• 2020

Recently, as the weight reduction of vehicles has been actively progressed, parts developed using aluminum 60XX series from existing steel materials are increasing. In this paper, the bushing used for the front frame rail, which is one of the parts for fixing engines and other parts in automobiles, was changed to an aluminum material of the Al60XX series, and it was intended to be produced by applying of cold forging method. The bushing is a part that secures the engine frame, and in order to produce it by cold forging, the molding limit is predicted through process design, and a multi-stage process is designed through finite element analysis. In addition, in order to verify the feasibility of the designed forging process, the limits of the multi-step process were verified based on the Cockcroft Latham theory, and the crack and overlap of the actual forging work were predicted and improved.

• 대한기계학회:학술대회논문집
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• 대한기계학회 2007년도 춘계학술대회A
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• pp.1570-1575
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• 2007

The cold-forging process analysed in this paper deals with the cam bolt of a nonaxisymmetric shape which mainly is used as a part in the steering system of a vehicle for the purpose of adjusting shock absorb. So both strength and endurance are very important for the cam bolt. In this study, cam bolt forging process is composed of four stage processes. For three forging stages, shape of workpiece will be eccentrical. And then bolt head and washer of eccentrical shape is created in last stage. 3D finite element analysis repeatedly has been performed with changing dimension of die to obtain adequate former multi forging process and die shape. Simulation results reviewed have influence on deciding design of die and forging process. As a result, Simulation results have provided a direction to improve the process.

• 한국기계가공학회지
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• 제19권5호
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• pp.75-81
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• 2020

Multistage hot forging process enables mass production of various parts at a high speed, wherein, it is important to design the forging steps in an optimal way. Finite element methods are widely applied for optimizing the forging process design; however, they present inaccurate results due to the rapid change in the mold temperature during multistage hot forging. In this study, the temperature distributions of the mold in a steady state were calculated via heat transfer analysis during mold cooling. The flow stress and friction coefficient of the material were measured according to the temperature and were applied for numerical analysis of the multistage hot forging process. Eventually, the accuracy of the analysis results is verified by comparing these results with the experiments.

• 소성∙가공
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• 제31권1호
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• pp.5-10
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• 2022

In multi-stage cold forging process, to enhance the productivity and product quality, in-site process monitoring technique by implanting sensors such as piezo-sensor and acoustic emission sensor has been continuously studied. For accurate analysis of the process, the selection of appropriate sensors and implantation positions are very important. Until now, in a multi-state forging machine, wedge parts located at the end of punch-set are used but it is difficult to analyze minute changes in die block-set. In this study, we also implanted sensors to the die part (die spacer) and compared signals from both sensors and found that sensing signals from die part showed enhanced process monitoring results.

• 한국산업융합학회 논문집
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• 제22권3호
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• pp.337-351
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• 2019

We Proposed a new technology to develop vertical type multi-joint robot system enable to adapt in high temperature environment. The main contents is a new approach to design a vertical type articulated robot with prismatic joint and analysis of thermal for process automation of casting and forging. The proposed robot is suitable to use handling working parts of casting and forging. for the manufacturing process of forging and casting. The reliability is illustrated that the proposed technique is more stable and robust than the conventional system. This study is concerned with an analytical methodology of kinematic computation for 7 DOF manipulators for optimization of forging manufacturing process.

• 한국기계가공학회지
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• 제20권12호
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• pp.8-15
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• 2021

Cold forging is a method in which molding is performed at room temperature. It has a high material recovery rate and dimensional precision and produces excellent surface quality, and it is mainly used for the production of bolted or housing products. The lifespan of cold forging molds is generally determined by the wear of the mold, plastic deformation of the mold, and fatigue strength. Cold forging molds are frequently damaged due to fatigue destruction rather than wear and plastic deformation in a high-temperature environment as it is molded at room temperature without preheating the raw material and mold. Based on the results analyzed through FEM, an effective mold structure design method was proposed by analyzing the changes in tensile and compressive stresses on molds according to the number of molds and reinforcement rings and comparing the product geometry and mold stress using three existing mold models.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 춘계학술대회 논문집
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• pp.546-550
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• 1996

A fully automatic computer simulation technique of axisymmetric multi-stage compound forging processes was presented in this paper. A penalty rigid-viscoplastic finite element method was employed together with an improved looping method for automatically remeshing with quadrilateral finite-elements only. An application example of six-stage axisymmetric forging processes involving one cold and two hot forging processes, two piercing processes and a sizing process was given with emphasis on automatically tracing the metal flow lines through the whole simulation.

• 소성∙가공
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• 제12권6호
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• pp.542-549
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• 2003

Three-dimensional forging analysis becomes an inevitable tool to make design process more reliable and more producible. In this study, in order to make the investigation for three-dimensional forging analysis more conveniently and accurately, a new post processor was developed. For post-processing of multi-stage forging simulation, efficient data structure was proposed and applied by using STL. New file architecture was developed to handle successive and huge data efficiently, common in three-dimensional forging analysis. Since sectioning and flow tracing plays an important role in the investigation of analysis result, we developed an algorithm suitable for 4-node and 10-node tetrahedron. This flow tracing algorithm can trace and reverse-trace flow through remeshing. Developed program shows good performance and functionality. Especially, a big size problem can be handled easily due to proposed data structure and file architecture.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2002년도 춘계학술대회 논문집
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• pp.666-669
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• 2002

Process design of hot forging, asymmetric to symmetric rail, which is used for the turnout of railway express has been investigated. Owing to the big difference in shape between the initial billet and the final forged product, it is impossible to hot forge the rail in a single step. Therefore, multi step forging as well as die design for each step are necessary for the production. The deformation behavior during hot forging has been analyzed by the numerical simulation through commercial FEA software, DEFORM$^{TM}$-2D. Modification of the design and repeated simulation have been carried out on the basis of the simulation result. For comparison with the simulation results, flow analysis experiment using plasticize has been also carried out. The results of the flow analysis experiment showed good agreement with those of the simulation. Therefore, the developed process design could be applied to the actual production.

• 소성∙가공
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• 제14권1호
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• pp.57-64
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• 2005

This study deals with the cold forging process design for shaft in the main part of automobile motors with rectangular deep groove. In forging process, the accuracy and die lift is very important because it have influence on reduction of the production cost and the increase of the production rate. Therefore, it is necessary to develop the manufacturing process of shaft by cold forging., process variables are the cropped face angle of billet and the eccentric load of punch. The former is derived from cropping test, the latter is occurred by clearance between container and preform. Also, grooved preform select the process variable for decrease in punch deflection. We investigate that a deflection of punch and a deformation of preform to every process variables. Through this investigation, we suggest the optimal preform and process design, expect to be improved the tool life in forging process.