• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2005년도 추계학술대회 논문집
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• pp.406-409
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• 2005

In the forging operation of large ingot two break-down process are upsetting and cogging. The first purpose of upsetting is to ensure sufficient forging ratio for subsequent cogging operations and consolidate the voids along the centerline. The second purpose is related to improve the physical properties for a final product. Voids which are generated during the casting process can be one of the decisive defects of materials. So it is necessary to know the standard of Judgment for void-closure in upsetting operation. In practical conditions, FEM analysis(DEFORM 2D 8.1) was carried out to decide how much effective strain has influence on void-closure. It is finally suggested that the function consists of the effective strain of analysis data and the area rate of void.

• 한국자동차공학회논문집
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• 제14권3호
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• pp.44-50
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• 2006

The mono steel forged piston was improved a mechanical strength of an aluminum piston and reduced the weight of a articulated piston. The mono steel forged piston was composed of forged crown part and forged skirt part and was completed by friction welding process of two forged parts. Forging process analysis and friction welding analysis was done by finite element simulation using numerical package DEFORM. The preform shape and the initial billet dimension were decided by maximum stress of the die, amount of the flash and filling of die. The upset length of friction welding variable was decided by the shape of the flash that was created by friction welding analysis. Through this research, we developed a forging process of the mono steel forged piston, and decided the design variables of friction welding.

• 소성∙가공
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• 제27권4호
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• pp.250-256
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• 2018

Oxygen-free copper (OFC) was prepared as a 90 mm cube and then processed with Multi-Axial Diagonal Forging - Initialization of Prior manufacturing History (MADF). The MADF process has been newly developed as a severe plastic deformation method. The MADF process consists of upset forging with a thickness reduction of 30% and diagonal forging with a diagonal angle of $135^{\circ}$. 1 cycle process consists of a 12 passes forging process. In order to analyze the characteristic changes according to the number of iterations, 1, 2, and 3 cycles of the MADF process were performed. The OFC specimens were MADF processed without surface cracks up to 3 cycles. The microstructure, hardness and tensile test of processed materials were analyzed to study the change of material properties according to the amount of MADF process. The results showed that the MADF process effectively refined the microstructure and increased the strength of OFC. In the case of specimens processed for more than 2 cycles, the grains of all measurement regions were refined to be less than $7{\mu}m$ of grain size. The 1 cycle MADF processed OFC showed the highest mechanical properties with the hardness of 132 HV and tensile strength of 395 MPa. Hardness and strength seemed to be saturated when processed over 2 cycles.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2003년도 춘계학술대회 논문집
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• pp.418-421
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• 2003

Specimens of Ti-10Ta-10Nb have been hot upset forged after heating to either the $\alpha$+$\beta$ and $\beta$-phase field. The variety temperatures (At 650, 700, 750, 800, 85$0^{\circ}C$) and strain rates (At 0.001, 0.01. 0.1, 1, 10 $s^{-1}$ ) were used. On the basis of flow stress data obtained as a function of temperature and strain rate in compression, a processing map for hot working has been developed. At strain rates lower than about 0.1 $s^{-1}$ and almost temperatures, processing efficiency exhibited high, but at 0.001 $s^{-l}$, and temperature 80$0^{\circ}C$, low because the Shear band has occurred. On the basis of the processing map, the optimum processing routes available for hot working of this material are outlined.d.

• 대한기계학회논문집
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• 제16권10호
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• pp.1877-1889
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• 1992

본 연구에서는 업셋팅의 변형해석 및 온도해석(열전달 해석)을 비연계 방식으 로 동시에 해석하고 실제 공정에 가깝게 접근하는 축대칭 열점소성 유한요소 프로그램 을 이용하여, 시뮬레이션에 의해 공정을 해석하여 불량감소 및 원가절감을 위해 단조 공정을 개선하는 것이다. 업셋팅공정의 연구에 있어서는 대형강괴의 주 불량요인인 기공의 소멸을 위한 공정방안을 연구하는데 있다.

• 소성∙가공
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• 제20권3호
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• pp.236-242
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• 2011

The two objectives of this study were, first, to determine the optimal friction welding process parameters using finite element simulations and, second, to evaluate the mechanical properties of the friction welded zone for large piston rods in marine diesel engines. Since the diameters of the rod and its connecting part are very different, the manufacturing costs using friction welding are reduced compared to those using the forging process of a single piece. Modeling is a generally accepted method to significantly reduce the number of experimental trials needed when determining the optimal parameters. Therefore, because friction welding depends on many process parameters such as axial force, initial rotational speed and energy, amount of upset and working time, finite element simulations were performed. Then, friction welding experiments were carried out with the optimal process parameter conditions resulting from the simulations. The base material used in this investigation was AISI 4140 with a rod outer diameter of 280 mm and an inner diameter of 160 mm. In this study, various investigation methods, including microstructure characterization, hardness measurements and tensile and fatigue testing, were conducted in order to evaluate the mechanical properties of the friction welded zone.

• Journal of Welding and Joining
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• 제32권3호
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• pp.95-101
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• 2014

Joining of grey cast iron by fusion welding has much difficulties for its extremely low ductility and low toughness because of the flake form of the graphite. And the brittle microstructure, i.e. ledeburite may be formed during fusion welding by its rapid cooling rates. By these kinds of welding problem, preheat and post heat treatment temperature must be increased to avoid weld crack or welding problems. In order to avoid these fusion welding problem, friction welding of cast iron was carried out for improving joint soundness, establishing friction welding variables. There is no factor for evaluating friction weldability in continuous drive type friction welding. In this point of view, this study proposed the parameters for calculating friction weld heat input. The results obtained are as follows ; 1. There was a close relationship between tensile strength and flash appearance of friction welded joint. 2. Tensile strength was decreased and flash was severely oxidized as increasing frictional heating time. 3. As increased forging pressure $P_2$, flash had a large crack and tensile strength was decreased. 4. As powdered graphite by rotational frictional force induced flat surface and hindered plastic flow of metal, tensile strength of welded joint was decreased. 5. Heat input for continuous drive type friction welding could be calculated by the factors of $P_1$, $P_2$ and upset distance(${\delta}$).