• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.6
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• pp.961-970
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• 1997

A numerical method is presented to predict and analyze the shape of a growing billet produced from the "spray forming process" which is a fairly new near-net shape manufacturing process. It is important to understand the mechanism of billet growing because one can obtain a billet with the desired final shape without secondary operations by accurate control of the billet shape, and it can also serve as a base for heat transfer and deformation analysis. The shape of a growing billet is determined by the flow rate of the alloy melt, the mode of nozzle scanning which is due to cam profile, the initial positio of the spray nozzle, scanning angle, and the withdrawal speed of the substrate. In the present study, a theoretical model is first established to predict the shape of the billet and next the effects of the most dominent processing conditions, such as withdrawal speed of the substrate and the cam profile, on the shape of the growing billet are studied. Process conditions are obtained to produce a billet with uniform diameter and flat top surface, and an ASP30 high speed steel billet is manufactured using the same process conditions established from the simulation.imulation.

• Transactions of Materials Processing
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• v.5 no.3
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• pp.239-255
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• 1996

A new forming technology has been developed to fabricate near-net shape products using light metal. A semi-solid forming technology has some advantages compared with the conventional forming processes such as die casting squeeze casting and hot/cold forging. In this study the numerical analysis of semi-solid filling for a straight die shape and orifice die shape in gate pattern is studied on semi-solid materials(SSM) of solid fraction fs =30% in A356 aluminum alloy. The finite difference program of Navier-Stokes equation coupled with heat transfer and solidification has been developed to predict a filling pattern and the temperature distribution of SSM. The programdeveloped in this study gives die filling patterns of SSM and final solidifica-tion region.

• Proceedings of the Korean Operations and Management Science Society Conference
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• 1994.04a
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• pp.467-477
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• 1994

The objective of this research is to develop a manufacturability measurement model for process and material screening. The process and material screening is the key requirement for implementing the Design for Manufacturability (Concurrent Engineering). A computerized system realizing this model then is developed to aid designers. Identification of the key factors which influence technical manufacturability, decision variables and their characteristics, conceptual framework for implementing the model are suggested. Manufacturability measure for quantifying the consistency of between the product requirements and the manufacturing capability is important contribution of this research. The focus is on net shape manufacturing process such as diecasting, forging, metal forming and injection molding.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.9 s.180
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• pp.2211-2219
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• 2000

Near net shape forming of 316L stainless steel powder was investigated under hot isostatic pressing. To simulate densification and deformation of a powder compact in a container during hot isostatic pressing, the constitutive model of Abouaf and co-workers was implemented into a finite element analysis. An optimal design technique based on the design sensitivity was applied to the container design during hot isostatic pressing. The optimal shape of the container was predicted from the desired final shape of a powder compact by iterative calculations. Experimental data of 316L stainless steel powder showed that the optimally designed container allowed precise forming of the desired powder compact during hot isostatic pressing.

• Transactions of Materials Processing
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• v.11 no.2
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• pp.123-131
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• 2002

The rheology process is net shape manufaturing technology to high of automobile part and improve the mechanical properties. For the rheology forming process, Phase and globular microstructure are very important. The equipments to make a rheology alloys with slurry statement have been introduced. Therefore, the Problems to Produce a rheology alloyas with continuous process had also been investigated to make Production in industries. The validity of the introduced rheology Process is investigated by comparing the reported thixoforming results. Therefore, the many advantage of rheology process to be reduced the reheating Process and billet fabrication method has been expressed in terms of mass production, in the future.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.4
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• pp.7-21
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• 2000

This paper describes an overview of the thixoforming and thixomolding processes. Semi-solid metalworking (SSM), which is called the thixoforming process of aluminium materials, incorporates the elements of both casting and for the manufacture of near net shape parts. The SSM has some advantages such as net shape or near net shape manufacturing, the ability to form thin walls, excellent surface finish, tight tolerance, and excellent dimensional precision. The thixomolding process of Mg alloy (AZ9l) is a combination of two technologies both conventional die casting and plastic injection molding. The feed material used is a machined chip with a geometry of approximately 1 mm square and a length of 2~3 mm. The semi-solid forming (SSF) of high quality aluminium and magnesium parts will be established in the automotive and electronic industry, in the future. The hybrid method of casting/forging has been caused attention. This process uses a preformed material made by casting instead of the wrought material and finishes it by a single forging process. This process is expected to lower costs without sacrificing the mechanical and finishes it by a single forging process. The process is expected to lower costs without sacrificing the mechanical properties. The authors, intending that the casting/forging process contributes to a reduction in production cost of aluminum automotive parts in Korea, describes the feature of the casting/forging process, aluminum alloys suitable for the cast preform, microstructure and mechanical properties of the cast preform, application examples of cast/forging, and further study.

• Transactions of Materials Processing
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• v.17 no.2
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• pp.124-129
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• 2008

Net shape forging technologies give many effects into the costs and qualities for the finished products. So, the studies to reduce the additional machining amount are very important in forging industry. Specially, there are two main topics in cold forging industry, such as, tool life and precision forging. In this study, new forging technique was proposed to eliminate the machining process for fixing up the length and improve the lead accuracy of gear. The luck-up hub is manufactured through many processes, such as upsetting, piercing and direct extrusion. The gear is formed in direct extrusion process; however, lead accuracy of the gear is over allowance limit. Therefore, the additional sizing process must be added. In this study, process design for closed-die forging of a lock-up hub used for a component of automobile transmission was made using three-dimensional finite element simulations, and the strain distributions and velocity distributions are investigated through the post processor. The rigid-plastic finite-element method for back pressure forging has been used in order to reduce development time and die cost. Using the FEM simulation, we found the optimum value of back pressure. The prototypes of lock-up hub parts were forged into the net-shape. In the experiment, lead precision of tooth are measured by the CCMM(Contact Coordinate Measuring Machine). The dimensional accuracy of forged part was improved up to the 40% when back press was applied.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.06a
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• pp.13-22
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• 1996

The quality requirements for metal forming products have become more strict. Machined parts, which could be produced only by cutting, can now be formed plastically. In order to reach the mechanical strength and geometrical accuracy, reasonable production technologies should be developed. In this presentation, some basic flow-press-technologies in the metal forming are introduced. Some real sample parts for a passenger can are shown and their forming plans are explained. Also problems and solutions for the production of bevel gears are discussed.

• Transactions of Materials Processing
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• v.16 no.8
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• pp.621-628
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• 2007

Nowadays, Exhaust Gas Recirculation(EGR) Cooler is one of the most favorite systems for reducing the generation amount of $NO_x$ and other particle materials from vehicles burning diesel as fuel. Efficiency of the system is mainly dependent on its heat transfer efficiency and this ability is affected by net heat transferring area of the system. For that reason, several types of heat transfer tube such as dimple, wrinkle and spiral types that have large net area are used. However, it is difficult to manufacture the rectangular tube with dimpled type structure because it experiences too much strain around the rectangular tube surface during the forming process. For that reason, in this study, numerical simulation for forming process of non-symmetric dimple shape on a thin sheet metal was carried out. Furthermore, theoretical forming limit curves(forming limit diagram, forming limit stress diagram) were proposed as criteria of formability evaluation. From the results of finite element simulation in view of stress and strain distribution, it is found that the designed process has robustness and feasibility to safely manufacture the dimpled rectangular tube.

• Journal of the Korea Institute of Military Science and Technology
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• v.8 no.3 s.22
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• pp.51-55
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• 2005

In this paper, a near net shape technology using superplasticity and diffusion bonding characteristics was presented for application to various components of aircraft and missiles. Due to these special characteristics of some aerospace alloys, it is possible to produce complex components to shape very near final dimension with enhanced design freedom, reduced material usage, and overall saving of weight and cost. The high pressure vessel for a space launcher was fabricated with Ti-6Al-4V alloy by superplastic forming and diffusion bonding process and the failure characteristics are compared with conventionally fabricated vessel spin formed and TIG welded. The structural integrity of the superplastic forming and diffusion bonding process was successfully demonstrated.